Professional Documents
Culture Documents
ENGINE
114E-3 SERIES
SEN00171-05
Engine
1SHOP MANUAL
114E-3 Series
Index
Composition of shop manual................................................................................................................ 2
Table of contents .................................................................................................................................. 3
114E-3 Series
SEN00171-05
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
File overview and other materials in sections in the order shown below and utilize them accordingly.
Section Title
Form Number
SEN00169-05
SEN00170-05
SEN00171-05 q
SEN00172-03
01 Specification
Specification and technical data
SEN00173-02
SEN00174-02
SEN00175-02
SEN00176-02
SEN00260-02
SEN00261-02
SEN00454-01
SEN00455-01 q
40 Troubleshooting
General information on troubleshooting
Troubleshooting of electrical system (E-mode), Part 1
Troubleshooting of electrical system (E-mode), Part 2
Troubleshooting of mechanical system (S-mode)
SEN00456-01
SEN00457-01
SEN00459-01
SEN00460-01
SEN00458-01
SEN00461-01
SEN00462-01 q
SEN00463-01 q
SEN00464-01 q
q
q
q
q
114E-3 Series
SEN00171-05
Table of contents
SEN00171-05
114E-3 Series
SEN00171-05
114E-3 Series
SEN00171-05
114E-3 Series
114E-3 Series
SEN00171-05
SEN00171-05
2007 KOMATSU
All Rights Reserved
Printed in Japan 05-07 (01)
SEN00172-03
Engine
1SHOP MANUAL
114E-3 Series
114E-3 Series
SEN00172-03
Safety notice
(Rev. 2007/03)
General precautions
k Mistakes in operation are extremely
dangerous. Read the Operation and
Maintenance Manual carefully before
operating the machine.
1) Before carrying out any greasing or
repairs, read all the safety plates stuck to
the machine. For the locations of the
safety plates and detailed explanation of
precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always
keep the tools and parts in their correct
places. Always keep the work area clean
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while
working.
3) When carrying out any operation, always
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with
buttons missing.
q
Always wear safety glasses when hitting parts with a hammer.
q
Always wear safety glasses when
grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or
more workers, always agree on the operating procedure before starting. Always
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, forklift, service car, etc.
7)
8)
Safety points
1 Good arrangement
2 Correct work clothes
3 Following work standard
4 Making and checking signs
5
2.
114E-3 Series
3)
4)
3.
114E-3 Series
SEN00172-03
8)
9)
10)
11)
12)
13)
14)
15)
16)
SEN00172-03
4.
8)
114E-3 Series
SEN00172-03
13) If the hoist stops because of a power failure, turn the power switch OFF. When
turning on a switch which was turned OFF
by the electric shock prevention earth
leakage breaker, check that the devices
related to that switch are not in operation
state.
14) If you find an obstacle around the hoist,
stop the operation.
15) After finishing the work, stop the hoist at
the specified position and raise the hook
to at least 2 m above the floor. Do not
leave the sling installed to the hook.
5.
6.
114E-3 Series
7.
Wire ropes
(Standard Z twist ropes without galvanizing)
(JIS G3525, No. 6, Type 6X37-A)
Nominal
Allowable load
diameter of rope
mm
kN
ton
10
8.8
0.9
12
12.7
1.3
14
17.3
1.7
16
22.6
2.3
18
28.6
2.9
20
35.3
3.6
25
55.3
5.6
30
79.6
8.1
40
141.6
14.4
50
221.6
22.6
60
318.3
32.4
SEN00172-03
8.
Precautions for disconnecting and connecting hoses and tubes in air conditioner
circuit
1) Disconnection
k Collect the air conditioner refrigerant (R134a) from the air conditioner circuit in advance.
a Ask professional traders for collecting
and filling operation of refrigerant
(R134a).
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas (R134a) gets
in your eyes, you may lose your
sight. Accordingly, when collecting or filling it, you must be qualified for handling the refrigerant
and put on protective goggles.
2)
Connection
1] When installing the air conditioner circuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not damaged or deteriorated.
4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8,
ZEXEL: ZXL100PG (equivalent to
PAG46)) to its O-rings.
114E-3 Series
1.
SEN00172-03
Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
Materials and specifications are subject to change without notice.
Shop manuals are divided into the Chassis volume and Engine volume. For the engine unit, see the
engine volume of the engine model mounted on the machine.
Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The S mode of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q
Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q
Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2.
114E-3 Series
SEN00172-03
3.
4.
Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q
Revisions
Revised brochures are shown in the shop manual composition table.
Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol
Item
Safety
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing work.
Weight
Tightening
torque
Coat
Oil, coolant
Drain
Remarks
Special safety precautions are necessary when performing work.
5.
Units
In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
114E-3 Series
SEN00172-03
The maintenance standard values necessary for judgment of products and parts are described by the following terms.
1.
Example:
Standard size
120
Tolerance
0.022
0.126
Example:
Standard size
60
114E-3 Series
Tolerance
Shaft
Hole
0.030
+0.046
0.076
+0
SEN00172-03
2.
5.
3.
4.
Standard interference
q
When the diameter of a hole of a part
shown in the given standard size and tolerance table is smaller than that of the
mating shaft, the difference between those
diameters is called the interference.
q
The range (A B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the standard interference.
q
After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
Clearance limit
Parts can be used until the clearance
between them is increased to a certain
limit. The limit at which those parts cannot
be used is called the clearance limit.
q
If the clearance between the parts
exceeds the clearance limit, they must be
replaced or repaired.
q
6.
Interference limit
The allowable maximum interference
between the hole of a part and the shaft of
another part to be assembled is called the
interference limit.
q
The interference limit shows the repair
limit of the part of smaller tolerance.
q
If the interference between the parts
exceeds the interference limit, they must
be replaced or repaired.
q
10
114E-3 Series
SEN00172-03
To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on Handling electric equipment and
Handling hydraulic equipment (particularly gear oil and hydraulic oil).
Points to remember when handling electric
equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, connectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2.
114E-3 Series
11
SEN00172-03
12
3)
Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the soldering may be damaged, or the wiring
may be broken.
4)
5)
114E-3 Series
3.
SEN00172-03
3]
114E-3 Series
13
SEN00172-03
2)
14
Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or damage to the connector pins.
Check that there is no damage or
breakage to the outside of the connector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or breakage, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stopper clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring harness.
For connectors fitted with boots, correct any protrusion of the boot. In
addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position.
a If the connector cannot be corrected easily, remove the clamp
and adjust the position.
q
If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
114E-3 Series
3)
114E-3 Series
SEN00172-03
Disconnection
Connection (Example of
incomplete setting of (a))
15
SEN00172-03
4)
16
114E-3 Series
4.
Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These control all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the controller.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness connectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5.
114E-3 Series
SEN00172-03
17
SEN00172-03
2.
3.
Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4.
18
114E-3 Series
5.
6.
Flushing operations
After disassembling and assembling the equipment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7.
Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment cannot remove, so it is an extremely effective
device.
114E-3 Series
SEN00172-03
19
SEN00172-03
1.
2.
20
114E-3 Series
3.
SEN00172-03
114 engine
3)
107 engine
2)
114E-3 Series
21
SEN00172-03
4)
4.
2)
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22
114E-3 Series
SEN00172-03
The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX
0.85
L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.
Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indicated.)
1.
(Table 1)
Type
Low-voltage
wire for
automobile
Thin-cover
low-voltage
wire for
automobile
Symbol
AV
AVS
Heat-resistant low-voltAEX
age wire for
automobile
114E-3 Series
Material
Conductor
Insulator
Conductor
Insulator
Conductor
Insulator
Using
temperature
range (C)
Example of use
General wiring
(Nominal No. 5 and above)
30 to +60
General wiring
(Nominal No. 3 and below)
General wiring in extremely
50 to +110 cold district, wiring at high-temperature place
23
SEN00172-03
2.
Dimensions
(Table 2)
Nominal No.
0.5f
(0.5)
0.75f
(0.85)
1.25f
(1.25)
2f
2
3f
3
5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51
0.56
0.76
0.88
1.27
1.29
1.96
2.09
3.08
3.30
5.23
area (mm2)
d (approx.)
1.0
1.2
1.5
1.9
1.9
2.3
2.4
3.0
AVS
Standard
2.0
2.2
2.5
2.9
2.9
3.5
3.6
CovAV
Standard
4.6
er D
AEX
Standard
2.0
2.2
2.7
3.0
3.1
3.8
4.6
Nominal No.
Number of
strands/Diameter of strand
Conductor
Sectional
area (mm2)
d (approx.)
AVS
Standard
CovAV
Standard
er D
AEX
Standard
15
20
30
40
50
60
85
100
50/0.45
84/0.45
41/0.80
70/0.80
85/0.80
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
3.7
5.5
5.3
4.8
7.0
7.0
6.0
8.2
8.2
8.0
10.8
10.8
8.6
11.4
11.4
9.8
13.0
13.0
10.4
13.6
13.6
12.0
16.0
16.0
13.6
17.6
17.6
24
114E-3 Series
3.
SEN00172-03
(Table 3)
Color Code
B
Br
BrB
BrR
BrW
BrY
Ch
Dg
G
GB
GL
Gr
GR
GW
GY
L
LB
Lg
LgB
LgR
Color of wire
Color Code
LgW
LgY
LR
LW
LY
O
P
R
RB
RG
RL
RW
RY
Sb
Y
YB
YG
YL
YR
YW
Black
Brown
Brown & Black
Brown & Red
Brown & White
Brown & Yellow
Charcoal
Dark green
Green
Green & Black
Green & Blue
Gray
Green & Red
Green & White
Green & Yellow
Blue
Blue & Black
Light green
Light green & Black
Light green & Red
Color of wire
Light green & White
Light green & Yellow
Blue & Red
Blue & White
Blue & Yellow
Orange
Pink
Red
Red & Black
Red & Green
Red & Blue
Red & White
Red & Yellow
Sky Blue
Yellow
Yellow & Black
Yellow &Green
Yellow & Blue
Yellow & Red
Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: GW means that the background is Green and marking is White.
4.
(Table 4)
Type of wire
Charge
Ground
Start
Light
Instrument
Signal
Type of
circuit
Others
114E-3 Series
AVS or AV
R
B
R
RW
Y
G
L
Br
Lg
O
Gr
P
Sb
Dg
Ch
AEX
R
B
R
D
Y
G
L
WG
RB
YR
GW
LW
BrW
LgR
RY
YB
GR
LR
BrR
LgY
RG
YG
GY
LY
BrY
LgB
RL
YL
GB
LB
BrB
LgW
YW
GL
Gr
Br
25
SEN00172-03
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1.
q
q
q
q
q
q
q
q
q
q
26
07376-70210
07376-70315
07376-70422
07376-70522
07376-70628
07376-71034
07376-71234
02789-20210
02789-20315
02789-20422
02789-20522
02789-20628
07221-21034
07221-21234
3)
Split flange
07379-00400
07379-00500
07378-10400
07378-10500
07371-30400
07371-30500
If the part is not under hydraulic pressure, the following corks can be used.
Nominal
number
Part Number
06
08
10
12
14
16
18
20
22
24
07049-00608
07049-00811
07049-01012
07049-01215
07049-01418
07049-01620
07049-01822
07049-02025
07049-02228
07049-02430
Dimensions
D
d
L
6
5
8
8
6.5
11
10
8.5
12
12
10
15
14
11.5
18
16
13.5
20
18
15
22
20
17
25
22
18.5
28
24
20
30
27
07049-02734
27
22.5
34
114E-3 Series
2.
q
q
q
q
q
q
q
q
q
q
q
q
q
a
3.
SEN00172-03
114E-3 Series
27
SEN00172-03
4)
5)
28
114E-3 Series
SEN00172-03
Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1.
Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2.
Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
114E-3 Series
29
SEN00172-03
Type 2
1.
2.
Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to disconnect it. (Fig. 8)
Connection
Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
30
114E-3 Series
SEN00172-03
Type 3
1.
2.
Disconnection
1) Hold the tightening portion and push body
(9) straight until sliding prevention ring (8)
contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal portion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to disconnect it. (Fig. 12)
Connection
Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)
114E-3 Series
31
SEN00172-03
a Fig. A
Tightening torque
Nm
kgm
11.8 14.7
1.2 1.5
27 34
2.8 3.5
59 74
6.0 7.5
98 123
10.0 12.5
153 190
15.5 19.5
235 285
23.5 29.5
320 400
33.0 41.0
455 565
46.5 58.0
610 765
62.5 78.0
785 980
80.0 100.0
1,150 1,440
118 147
1,520 1,910
155 195
1,960 2,450
200 250
2,450 3,040
250 310
2,890 3,630
295 370
32
Tightening torque
Nm
5.9 9.8
13.7 23.5
34.3 46.1
74.5 90.2
kgm
0.6 1.0
1.4 2.4
3.5 4.7
7.6 9.2
a Fig. B
114E-3 Series
2.
3.
Tightening torque
Nm
kgm
59 74
6.0 7.5
98 123
10.0 12.5
235 285
23.5 29.5
Nominal No.
02
03,04
05,06
10,12
14
4.
SEN00172-03
Thread diameter
mm
8
10
12
14
16
18
20
24
30
33
36
42
52
114E-3 Series
36
33
SEN00172-03
5.
Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm}
Nominal
No. of
hose
Width
across
flats
02
19
03
04
05
06
(10)
(12)
(14)
6.
22
24
27
32
36
41
46
55
Range
34 54 { 3.5 5.5}
34 63 { 3.5 6.5}
54 93 { 5.5 9.5}
59 98 { 6.0 10.0}
84 132 { 8.5 13.5}
128 186 {13.0 19.0}
177 245 {18.0 25.0}
177 245 {18.0 25.0}
197 294 {20.0 30.0}
246 343 {25.0 35.0}
Target
44 { 4.5}
74 { 7.5}
78 { 8.0}
103 {10.5}
157 {16.0}
216 {22.0}
216 {22.0}
245 {25.0}
294 {30.0}
mm
6
8
10
12
14
14
18
22
24
30
33
36
42
Tightening torque
Bolts and nuts
Nm
10 2
24 4
43 6
77 12
kgm
1.02 0.20
2.45 0.41
4.38 0.61
7.85 1.22
Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size
mm
6
8
10
12
14
34
Thread size
(mm)
Face seal
Nominal No. Thread diameNumber of
ter (mm) (Refthreads, type of
erence)
thread
9/16-18UN
14.3
11/16-16UN
17.5
13/16-16UN
20.6
1-14UNS
25.4
1-3/16-12UN
30.2
Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Thread size
7.
Taper seal
Tightening torque
Nm
82
10 2
12 2
24 4
36 5
kgm
0.81 0.20
1.02 0.20
1.22 0.20
2.45 0.41
3.67 0.51
114E-3 Series
8.
SEN00172-03
Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Thread size
inch
1/16
1/8
1/4
3/8
1/2
3/4
1
114E-3 Series
Tightening torque
Nm
31
82
12 2
15 2
24 4
36 5
60 9
kgm
0.31 0.10
0.81 0.20
1.22 0.20
1.53 0.20
2.45 0.41
3.67 0.51
6.12 0.92
35
SEN00172-03
Conversion table
2.
Millimeters to inches
(A)
36
(B)
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
5
0.197
0.591
0.984
1.378
1.772
(C)
2.165
2.559
2.953
3.346
3.740
6
0.236
0.630
1.024
1.417
1.811
7
0.276
0.669
1.063
1.457
1.850
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
1 mm = 0.03937 in
8
9
0.315
0.354
0.709
0.748
1.102
1.142
1.496
1.536
1.890
1.929
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
114E-3 Series
SEN00172-03
Millimeters to inches
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
5
0.197
0.591
0.984
1.378
1.772
6
0.236
0.630
1.024
1.417
1.811
1 mm = 0.03937 in
7
8
9
0.276
0.315
0.354
0.669
0.709
0.748
1.063
1.102
1.142
1.457
1.496
1.536
1.850
1.890
1.929
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
2.165
2.559
2.953
3.346
3.740
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
1 kg = 2.2046 lb
6
7
8
9
13.23
15.43
17.64
19.84
35.27
37.48
39.68
41.89
57.32
59.53
61.73
63.93
79.37
81.57
83.78
85.98
101.41 103.62 105.82 108.03
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
Kilogram to pound
0
10
20
30
40
0
0
22.05
44.09
66.14
88.18
1
2.20
24.25
46.30
68.34
90.39
2
4.41
26.46
48.50
70.55
92.59
3
6.61
28.66
50.71
72.75
94.80
4
8.82
30.86
51.91
74.96
97.00
5
11.02
33.07
55.12
77.16
99.21
50
60
70
80
90
110.23
132.28
154.32
176.37
198.42
112.44
134.48
156.53
178.57
200.62
114.64
136.69
158.73
180.78
202.83
116.85
138.89
160.94
182.98
205.03
119.05
141.10
163.14
185.19
207.24
121.25
143.30
165.35
187.39
209.44
123.46
145.51
167.55
189.60
211.64
125.66
147.71
169.76
191.80
213.85
127.87
149.91
171.96
194.01
216.05
130.07
152.12
174.17
196.21
218.26
0
10
20
30
40
0
1
2
0
0.264
0.528
2.642
2.906
3.170
5.283
5.548
5.812
7.925
8.189
8.454
10.567 10.831 11.095
3
0.793
3.434
6.076
8.718
11.359
4
1.057
3.698
6.340
8.982
11.624
1 l = 0.2642 U.S.Gal
5
6
7
8
9
1.321 1.585
1.849
2.113
2.378
3.963 4.227
4.491
4.755
5.019
6.604 6.869
7.133
7.397
7.661
9.246 9.510
9.774 10.039 10.303
11.888 12.152 12.416 12.680 12.944
50
60
70
80
90
13.209
15.850
18.492
21.134
23.775
14.001
16.643
19.285
21.926
24.568
14.265
16.907
19.549
22.190
24.832
14.529
17.171
19.813
22.455
25.096
114E-3 Series
13.473
16.115
18.756
21.398
24.040
13.737
16.379
19.020
21.662
24.304
14.795
17.435
20.077
22.719
25.361
15.058
17.700
20.341
22.983
25.625
15.322
17.964
20.605
23.247
25.889
15.586
18.228
20.870
23.511
26.153
37
SEN00172-03
0
10
20
30
40
0
0
2.200
4.399
6.599
8.799
1
0.220
2.420
4.619
6.819
9.019
2
0.440
2.640
4.839
7.039
9.239
3
0.660
2.860
5.059
7.259
9.459
4
0.880
3.080
5.279
7.479
9.679
5
1.100
3.300
5.499
7.699
9.899
50
60
70
80
90
10.998
13.198
15.398
17.598
19.797
11.281
13.418
15.618
17.818
20.017
11.438
13.638
15.838
18.037
20.237
11.658
13.858
16.058
18.257
20.457
11.878
14.078
16.278
18.477
20.677
12.098
14.298
16.498
18.697
20.897
1 l = 0.21997 U.K.Gal
6
7
8
9
1.320
1.540
1.760
1.980
3.520
3.740
3.950
4.179
5.719
5.939
6.159
6.379
7.919
8.139
8.359
8.579
10.119 10.339 10.559 10.778
12.318
14.518
16.718
18.917
21.117
12.528
14.738
16.938
19.137
21.337
12.758
14.958
17.158
19.357
21.557
12.978
15.178
17.378
19.577
21.777
kgm to ft.lb
0
10
20
30
40
0
0
72.3
144.7
217.0
289.3
1
7.2
79.6
151.9
224.2
296.6
2
14.5
86.8
159.1
231.5
303.8
3
21.7
94.0
166.4
238.7
311.0
4
28.9
101.3
173.6
245.9
318.3
5
36.2
108.5
180.8
253.2
325.5
6
43.4
115.7
188.1
260.4
332.7
50
60
70
80
90
361.7
434.0
506.3
578.6
651.0
368.9
441.2
513.5
585.9
658.2
376.1
448.5
520.8
593.1
665.4
383.4
455.7
528.0
600.3
672.7
390.6
462.9
535.2
607.6
679.9
397.8
470.2
542.5
614.8
687.1
405.1
477.4
549.7
622.0
694.4
412.3
484.6
556.9
629.3
701.6
419.5
491.8
564.2
636.5
708.8
426.8
499.1
571.4
643.7
716.1
100
110
120
130
140
723.3
730.5
737.8 745.0
752.2
759.5 766.7
773.9
781.2
788.4
795.6
802.9
810.1 817.3
824.6
831.8 839.0
846.3
853.5
860.7
868.0
875.2
882.4 889.7
896.9
904.1
911.4
918.6
925.8
933.1
940.3
947.5
954.8 962.0
969.2
976.5 983.7
990.9
998.2 1005.4
1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150
160
170
180
190
1084.9
1157.3
1129.6
1301.9
1374.3
38
1092.2
1164.5
1236.8
1309.2
1381.5
1099.4
1171.7
1244.1
1316.4
1388.7
1106.6
1179.0
1251.3
1323.6
1396.0
1113.9
1186.2
1258.5
1330.9
1403.2
1121.1
1193.4
1265.8
1338.1
1410.4
1128.3
1200.7
1273.0
1345.3
1417.7
1135.6
1207.9
1280.1
1352.6
1424.9
1142.8
1215.1
1287.5
1359.8
1432.1
1150.0
1222.4
1294.7
1367.0
1439.4
114E-3 Series
SEN00172-03
kg/cm2 to lb/in2
0
10
20
30
40
0
0
142.2
284.5
426.7
568.9
1
14.2
156.5
298.7
440.9
583.2
2
28.4
170.7
312.9
455.1
597.4
3
42.7
184.9
327.1
469.4
611.6
4
56.9
199.1
341.4
483.6
625.8
5
71.1
213.4
355.6
497.8
640.1
6
85.3
227.6
369.8
512.0
654.3
50
60
70
80
90
711.2
853.4
995.6
1,138
1,280
725.4
867.6
1,010
1,152
1,294
739.6
881.8
1,024
1,166
1,309
753.8
896.1
1,038
1,181
1,323
768.1
910.3
1,053
1,195
1,337
782.3
924.5
1,067
1,209
1,351
796.5
938.7
1,081
1,223
1,365
810.7
953.0
1,095
1,237
1,380
825.0
967.2
1,109
1,252
1,394
839.2
981.4
1,124
1,266
1,408
100
110
120
130
140
1,422
1,565
1,707
1,849
1,991
1,437
1,579
1,721
1,863
2,005
1,451
1,593
1,735
1,877
2,020
1,465
1,607
1,749
1,892
2,034
1,479
1,621
1,764
1,906
2,048
1,493
1,636
1,778
1,920
2,062
1,508
1,650
1,792
1,934
2,077
1,522
1,664
1,806
1,949
2,091
1,536
1,678
1,821
1,963
2,105
1,550
1,693
1,835
1,977
2,119
150
160
170
180
190
2,134
2,276
2,418
2,560
2,702
2,148
2,290
2,432
2,574
2,717
2,162
2,304
2,446
2,589
2,731
2,176
2,318
2,460
2,603
2,745
2,190
2,333
2,475
2,617
2,759
2,205
2,347
2,489
2,631
2,773
2,219
2,361
2,503
2,646
2,788
2,233
2,375
2,518
2,660
2,802
2,247
2,389
2,532
2,674
2,816
2,262
2,404
2,546
2,688
2,830
200
210
220
230
240
2,845
2,987
3,129
3,271
3,414
2,859
3,001
3,143
3,286
3,428
2,873
3,015
3,158
3,300
3,442
2,887
3,030
3,172
3,314
3,456
2,901
3,044
3,186
3,328
3,470
2,916
3,058
3,200
3,343
3,485
2,930
3,072
3,214
3,357
3,499
2,944
3,086
3,229
3,371
3,513
2,958
3,101
3,243
3,385
3,527
2,973
3,115
3,257
3,399
3,542
114E-3 Series
39
SEN00172-03
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
F
40.4
37.2
34.4
31.7
28.9
40
35
30
25
20
40.0
31.0
22.0
13.0
4.0
11.7
11.1
10.6
10.0
9.4
11
12
13
14
15
51.8
53.6
55.4
57.2
59.0
7.8
8.3
8.9
9.4
10.0
46
47
48
49
50
114.8
116.6
118.4
120.2
122.0
27.2
27.8
28.3
28.9
29.4
81
82
83
84
85
177.8
179.6
181.4
183.2
185.0
28.3
27.8
27.2
26.7
26.1
19
18
17
16
15
2.2
0.4
1.4
3.2
5.0
8.9
8.3
7.8
7.2
6.7
16
17
18
19
20
60.8
62.6
64.4
66.2
68.0
10.6
11.1
11.7
12.2
12.8
51
52
53
54
55
123.8
125.6
127.4
129.2
131.0
30.0
30.6
31.1
31.7
32.2
86
87
88
89
90
186.8
188.6
190.4
192.2
194.0
25.6
25.0
24.4
23.9
23.3
14
13
12
11
10
6.8
8.6
10.4
12.2
14.0
6.1
5.6
5.0
4.4
3.9
21
22
23
24
25
69.8
71.6
73.4
75.2
77.0
13.3
13.9
14.4
15.0
15.6
56
57
58
59
60
132.8
134.6
136.4
138.2
140.0
32.8
33.3
33.9
34.4
35.0
91
92
93
94
95
195.8
197.6
199.4
201.2
203.0
22.8
22.2
21.7
21.1
20.6
9
8
7
6
5
15.8
17.6
19.4
21.2
23.0
3.3
2.8
2.2
1.7
1.1
26
27
28
29
30
78.8
80.6
82.4
84.2
86.0
16.1
16.7
17.2
17.8
18.3
61
62
63
64
65
141.8
143.6
145.4
147.2
149.0
35.6
36.1
36.7
37.2
37.8
96
97
98
99
100
204.8
206.6
208.4
210.2
212.0
20.0
19.4
18.9
18.3
17.8
4
3
2
1
0
24.8
26.6
28.4
30.2
32.0
0.6
0
0.6
1.1
1.7
31
32
33
34
35
87.8
89.6
91.4
93.2
95.0
18.9
19.4
20.0
20.6
21.1
66
67
68
69
70
150.8
152.6
154.4
156.2
158.0
40.6
43.3
46.1
48.9
51.7
105
110
115
120
125
221.0
230.0
239.0
248.0
257.0
17.2
16.7
16.1
15.6
15.0
1
2
3
4
5
33.8
35.6
37.4
39.2
41.0
2.2
2.8
3.3
3.9
4.4
36
37
38
39
40
96.8
98.6
100.4
102.2
104.0
21.7
22.2
22.8
23.3
23.9
71
72
73
74
75
159.8
161.6
163.4
165.2
167.0
54.4
57.2
60.0
62.7
65.6
130
135
140
145
150
266.0
275.0
284.0
293.0
302.0
14.4
13.9
13.3
12.8
12.2
6
7
8
9
10
42.8
44.6
46.4
48.2
50.0
5.0
5.6
6.1
6.7
7.2
41
42
43
44
45
105.8
107.6
109.4
111.2
113.0
24.4
25.0
25.6
26.1
26.7
76
77
78
79
80
168.8
170.6
172.4
174.2
176.0
68.3
71.1
73.9
76.7
79.4
155
160
165
170
175
311.0
320.0
329.0
338.0
347.0
40
114E-3 Series
114E-3 Series
SEN00172-03
41
SEN00172-03
2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (01)
42
SEN00174-02
Engine
1SHOP MANUAL
114E-3 Series
01 Specification
114E-3 Series
SEN00174-02
01 Specification
1. Applicable machine
Engine
SAA6D114E-3
Serial No.
Applicable machine
PC300-7E0, PC300LC-7E0
PC350-7E0, PC350LC-7E0
PC300-8, PC300LC-8
PC350-8, PC350LC-8
WA430-6
D65EX-15E0, D65PX-15E0, D65WX-15E0
GD655-3E0, GD675-3E0
Hydraulic excavator
Hydraulic excavator
Hydraulic excavator
Hydraulic excavator
Wheel loader
Bulldozer
Motor grader
114E-3 Series
01 Specification
SEN00174-02
Specifications
1
Engine name
SAA6D114E-3
Applicable model
PC300-7E0, PC300LC-7E0
PC350-7E0, PC350LC-7E0
mm
6 114 135
l {cc}
8.27 {8,270}
153624
Overall length
mm
1,625
Overall width
mm
1,004
mm
mm
1,601
kW{HP}/rpm
194 {260}/1,950
(Gross)
Nm{kgm}/rpm
1,129 {115}/1,450
(Gross)
rpm
2,050 50
rpm
1,000 25
g/kWh
{g/HPh}
226 {168}
kg
865
Dimensions
Firing order
Performance
Flywheel horsepower
Max. torque
HPCR
Electronic control type
40 (35)
Coolant amount
10.4
Alternator
Starting motor
Battery
12V, 120Ah/140Ah 2
Turbocharger
HOLSET HX40W
Air compressor
Others
114E-3 Series
SEN00174-02
01 Specification
1
Engine name
SAA6D114E-3
Applicable model
PC300-8, PC300LC-8
PC350-8, PC350LC-8
mm
6 114 135
l {cc}
8.27 {8,270}
153624
Overall length
mm
1,625
Overall width
mm
1,004
mm
mm
1,601
kW{HP}/rpm
194 {260}/1,950
(Gross)
Nm{kgm}/rpm
1,129 {115}/1,450
(Gross)
rpm
2,050 50
rpm
1,000 25
g/kWh
{g/HPh}
226 {168}
kg
865
Dimensions
Firing order
Performance
Flywheel horsepower
Max. torque
HPCR
Electronic control type
40 (35)
Coolant amount
10.4
Alternator
24V, 60A
Starting motor
Battery
12V, 120Ah/140Ah 2
Turbocharger
HOLSET HX40W
Air compressor
Others
114E-3 Series
01 Specification
SEN00174-02
1
Engine name
SAA6D114E-3
Applicable model
WA430-6
mm
6 114 135
l {cc}
8.27 {8,270}
153624
Overall length
mm
1,135
Overall width
mm
844
mm
mm
1,605
Flywheel horsepower
kW{HP}/rpm
173 {232}/2,100
(Gross)
Max. torque
Nm{kgm}/rpm
1,020 {104}/1,450
(Gross)
rpm
2,245 50
rpm
765 25
g/kWh
{g/HPh}
235 {175}
kg
785
Performance
Dimensions
Firing order
HPCR
Electronic control type
37 (32)
Coolant amount
10.4
Alternator
Starting motor
Battery
12V, 136Ah/140Ah 2
Turbocharger
HOLSET HX40W
Air compressor
Equipped
Others
114E-3 Series
SEN00174-02
01 Specification
1
Engine name
SAA6D114E-3
Applicable model
mm
6 114 135
l {cc}
8.27 {8,270}
153624
Overall length
mm
1,189
Overall width
mm
909
mm
mm
1,532
Flywheel horsepower
kW{HP}/rpm
154 {206}/1,950
(Gross)
Max. torque
Nm{kgm}/rpm
1,010 {103}/1,450
(Gross)
rpm
2,030 50
rpm
825 25
g/kWh
{g/HPh}
227 {169}
kg
860
Performance
Dimensions
Firing order
HPCR
Electronic control type
33 (28)
Coolant amount
10.4
Alternator
Starting motor
Battery
12V, 112Ah/140Ah 2
Turbocharger
HOLSET HX40W
Air compressor
Others
114E-3 Series
01 Specification
SEN00174-02
1
Engine name
SAA6D114E-3
Applicable model
GD655-3E0, GD675-3E0
mm
6 114 135
l {cc}
8.27 {8,270}
153624
Overall length
mm
1,128
Overall width
mm
872
mm
mm
1,455
Flywheel horsepower
kW{HP}/rpm
154 {206}/1,900
(Gross)
Max. torque
Nm{kgm}/rpm
990 {101}/1,450
(Gross)
rpm
2,225 50
rpm
825 25
g/kWh
{g/HPh}
232 {173}
kg
800
Performance
Dimensions
Firing order
HPCR
Electronic control type
30 (25)
Coolant amount
10.4
Alternator
Starting motor
Battery
12V, 112Ah 2
Turbocharger
HOLSET HX40W
Air compressor
Others
114E-3 Series
SEN00174-02
General view
01 Specification
1.
2.
Crankshaft center
Flywheel housing rear surface
114E-3 Series
01 Specification
SEN00174-02
1.
2.
Crankshaft center
Flywheel housing rear surface
114E-3 Series
SEN00174-02
01 Specification
1.
2.
Crankshaft center
Cylinder center
10
114E-3 Series
01 Specification
SEN00174-02
1.
2.
Crankshaft center
Cylinder center
114E-3 Series
11
SEN00174-02
01 Specification
Dimensions table
1
Unit: mm
Engine
SAA6D114E-3
12
Machine model
PC300-7E0, PC300LC-7E0
PC350-7E0, PC350LC-7E0
PC300-8, PC300LC-8
PC350-8, PC350LC-8
1,625
1,601
1,004
WA430-6
1,135
1,605
844
1,189
1,532
909
GD655-3E0, GD675-3E0
1,128
1,455
872
These dimensions are given for reference when the engine is set on a test bench.
114E-3 Series
01 Specification
SEN00174-02
SAA6D114E-3
114E-3 Series
Machine model
Page
PC300-7E0, PC300LC-7E0
PC350-7E0, PC350LC-7E0
PC300-8, PC300LC-8
PC350-8, PC350LC-8
14
WA430-6
15
16
GD655-3E0, GD675-3E0
17
13
SEN00174-02
01 Specification
SAA6D114E-3
(Machine model: PC300-7E0, PC300LC-7E0, PC350-7E0, PC350LC-7E0,
PC300-8, PC300LC-8, PC350-8, PC350LC-8)
1
1
14
114E-3 Series
01 Specification
SEN00174-02
114E-3 Series
15
SEN00174-02
01 Specification
16
114E-3 Series
01 Specification
SEN00174-02
114E-3 Series
17
SEN00174-02
2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (01)
18
SEN00176-02
Engine
1SHOP MANUAL
114E-3 Series
SEN00176-02
1
1
General Information
1.
2.
3.
4.
5.
114E-3 Series
Exhaust system
SEN00176-02
General Information
1.
2.
3.
4.
Exhaust valve
Exhaust manifold (pulse type)
Dual-entry turbocharger
Turbocharger exhaust outlet
114E-3 Series
SEN00176-02
Turbocharger
General Information
Exhaust in
Sliding nozzle open
Exhaust gas low velocity flow
4.
5.
The turbine, compressor wheels, and shaft are supported by two rotating bearings in the bearing housing. Passages in the bearing housing direct filtered,
pressurized engine oil to the shaft bearings and
thrust bearings. The oil is used to lubricate and cool
the rotating components. Oil then drains from the
bearing housing to the engine sump, through the oil
drain line.
a An adequate supply of good, filtered oil is very
important to the life of the turbocharger. Make
sure that a high-quality oil is used and that it
and the oil filter are changed according to
maintenance recommendations.
114E-3 Series
SEN00176-02
114E-3 Series
SEN00176-02
The wastegate actuator is mounted on the turbocharger and consists of a pressure canister, diaphragm, and rod. As the pressure changes in the
canister, as dictated by the wastegate controller,
the actuator rod adjusts the wastegate valve
accordingly.
The wastegate valve is mounted inside the turbocharger in the turbine housing. As the valve opens,
exhaust gas is allowed to bypass the turbine wheel,
lowering turbine speed to adjust the intake manifold
pressure.
114E-3 Series
SEN00176-02
General Information
5.
6.
114E-3 Series
5.
6.
SEN00176-02
114E-3 Series
Cooling system
SEN00176-02
General Information
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
114E-3 Series
SEN00176-02
General Information
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
10
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
114E-3 Series
SEN00176-02
High pressure
pump
Main filter
Priming pump
Pre-filter
Fuel tank
114E-3 Series
11
SEN00176-02
12
114E-3 Series
SEN00176-02
The lift pump will run for 30 seconds after the key is
switched on to assist with fuel priming. The lift
pump will run during cranking and while the engine
is running until the 30 seconds has lapsed. The lift
pump will shut off anytime the key is switched
OFF. The 30 second timer is reset after each key
switch cycle and ECM power down.
114E-3 Series
13
SEN00176-02
High-pressure common rail fuel systems use solenoid-actuated injectors. High-pressure fuel flows
into the side of the injector. When the solenoid is
activated, an internal needle lifts and fuel is
injected. The clearances in the nozzle bore are
extremely small and any dirt or contaminants will
cause the injector to stick.
This is why it is important to clean around all fuel
connections before servicing the fuel system. Also,
cap or cover any open fuel connections before a
fuel system repair is performed.
14
114E-3 Series
SEN00176-02
Maintenance standard
Turbocharger
1
1
Unit: mm
No.
Check item
Criteria
Remedy
0.330 0.508
Replace bearing
parts
0.025 0.127
Replace thrust
parts
114E-3 Series
Tighten
15
SEN00176-02
Cylinder head
16
114E-3 Series
SEN00176-02
Unit: mm
No.
1
Check item
Strain of cylinder head mounting face
Projection of nozzle
114E-3 Series
Criteria
Remedy
End-to-End
Max. 0.203
Side-to-Side
Max. 0.075
Procedure
1st stage
150 {15.3}
2nd stage
Loosen
3rd stage
110 {11.2}
4th stage
110 {11.2}
5th stage
Retighten 120
2.25 2.80
Tighten and
retighten
Replace nozzle
or gasket
Tighten
24 {2.4}
17
SEN00176-02
Cylinder block
18
114E-3 Series
SEN00176-02
Unit: mm
No.
Check item
Criteria
Remedy
End-to-End
Max. 0.075
Side-to-Side
Max. 0.075
3.446 3.454
Replace bearing
metal
Max. 64.013
Correct or replace
block
Max. 60.120
Replace cam
bushing
Procedure
1st stage
167 {17.0}
2nd stage
Loosen 360
3rd stage
30.4 {3.1}
4th stage
50 {5.1}
5th stage
6
114E-3 Series
Tighten and
retighten
Retighten 120
Target (Nm {kgm})
28 {2.8}
Tighten
200 {20.4}
19
SEN00176-02
Cylinder liner
20
114E-3 Series
SEN00176-02
Unit: mm
No.
Check item
Criteria
114.000 114.040
Remedy
Replace cylinder
liner
0.026 0.122
Replace cylinder
liner or cylinder
block
130.938 13.0958
Replace cylinder
liner
130.900 13.0950
114E-3 Series
Min. 0.229
Replace cylinder
liner or cylinder
block
21
SEN00176-02
Crankshaft
Unit: mm
No.
1
Check item
End play
Outside diameter of main journal
Roundness of main journal
Criteria
Remedy
0.085 0.385
Replace thrust
bearing metal or
use oversize metal
76.000 76.026
Repair limit: 0.050
Max. 0.013
0.038 0.116
75.987 76.006
75.898 75.923
22
Use undersize
journal or replace
Replace main
bearing metal
Use undersize
crankshaft or
replace
114E-3 Series
SEN00176-02
Unit: mm
No.
Check item
Criteria
Top ring
0.30 0.45
2nd ring
0.85 1.15
Oil ring
0.30 0.73
44.997 45.003
45.006 45.012
114E-3 Series
Remedy
Replace piston
ring or piston
Peplace piston or
piston pin
23
SEN00176-02
Connecting rod
24
114E-3 Series
SEN00176-02
Unit: mm
No.
Check item
Criteria
Remedy
Replace bushing
(spare part is
semi-finished part)
45.023 45.035
76.045 76.095
114E-3 Series
2.459 2.471
80.987 81.013
Procedure
1st stage
60 {6.1}
2nd stage
Loosen
3rd stage
70 {7.1}
4th stage
Retighten 60
0.100 0.300
Tighten and
retighten
25
SEN00176-02
Vibration damper
Unit: mm
No.
1
26
Check item
Tightening torque of vibration damper
Criteria
Target (Nm {kgm})
200 {20.4}
Remedy
Tighten and
retighten
114E-3 Series
SEN00176-02
Timing gear
Unit: mm
No.
Check item
114E-3 Series
Criteria
Remedy
0.08 0.33
Backlash of camshaft
gear
0.08 0.33
0.08 0.33
Replace
27
SEN00176-02
Camshaft
Unit: mm
No.
Check item
End play
28
Criteria
0.12 0.50
59.962 60.013
9.40 9.60
Target (Nm {kgm})
24 {2.4}
Remedy
Replace thrust
plate
Correct or replace
Replace
Tighten
114E-3 Series
114E-3 Series
SEN00176-02
29
SEN00176-02
30
114E-3 Series
SEN00176-02
Unit: mm
No.
Check item
Criteria
Remedy
0.84 1.32
Replace valve or
valve seat
Intake
Min. 2.20
Exhaust
Min. 1.83
Valve
Angle
Intake
30
Exhaust
45
Repair limit
Judge condition of contact
surface with vacuum test
8.019 8.071
13.15 13.65
114E-3 Series
Replace
7.96 7.98
Correct or replace
valve, valve seat
Replace
Correct
31
SEN00176-02
32
114E-3 Series
SEN00176-02
Unit: mm
No.
Check item
Criteria
Remedy
Min. 21.965
Replace rocker
arm shaft
Max. 22.027
Replace rocker
arm
Max. 0.062
Replace rocker
arm or shaft
5
6
7
114E-3 Series
Repair limit
Intake
0.305
Exhaust
0.559
15.936 15.977
Target (Nm {kgm})
65 {6.6}
Tighten
Adjust
Replace tappet
Tighten
33
SEN00176-02
34
114E-3 Series
SEN00176-02
Unit: mm
No.
Check item
Criteria
Remedy
77 {7.85}
Flywheel
Limit
For clutch
0.013 / 25.4
For torque
converter
114E-3 Series
137 {14.0}
Reassemble,
correct
Tighten
Reassemble,
correct
Tigthen and
retighten
35
SEN00176-02
Oil pump
Unit: mm
No.
Check item
Criteria
0.025 0.127
0.178 0.381
0.025 0.178
36
Remedy
Tigthen and
retighten
114E-3 Series
114E-3 Series
SEN00176-02
37
SEN00176-02
2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (01)
38
SEN00261-02
Engine
1SHOP MANUAL
114E-3 Series
114E-3 Series
SEN00261-02
Engine model
SAA6D114E-3
Applicable machine
Prerformance
Item
Unit
Standard value
Permissible value
rpm
2,050 50
2,050 50
rpm
1,000 25
1,000 25
Necessary starting
speed
At 0C
rpm
At 20C
rpm
70
Intake resistance
At all speed
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Intake pressure
(Air connector outlet)
At rated horsepower
kPa
{mmHg}
135 175
{1,010 1,310}
100
{750}
Exhaust pressure
(Turbine inlet press.)
At rated horsepower
kPa
{mmHg}
127 167
{950 1,250}
100
{750}
Exhaust temperature
(Turbine outlet temp.)
Max. 600
Max. 650
Max. 1.0
Max. 2.0
Max. 25
Max. 35
Engine speed
At rated horsepower
Exhaust gas color
Cooling system
Lubrication system
Engine body
Valve clearance
Condition, etc
Compression pressure
Blow-by pressure
Oil pressure
Quick acceleration
(Low idle o high idle)
Intake valve
mm
0.305
0.152 0.559
Exhaust valve
mm
0.559
0.381 0.813
MPa
{kg/cm2}
Min. 2.6
{Min. 26.5}
2.1
{21.4}
kPa
{mmH2O}
Max. 1.57
{Max. 160}
Max. 2.55
{Max. 260}
At rated horsepower
(Oil temperature: Min. 80C)
SAE15W-40
MPa
{kg/cm2}
0.34 0.59
{3.5 6.0}
0.21
{2.1}
At low idle
(Oil temperature: Min. 80C)
SAE15W-40
MPa
{kg/cm2}
Min. 0.15
{Min. 1.5}
0.08
{0.8}
Oil temperature
At all speed
(Oil in oil pan)
80 110
120
At continuous rated
(Ratio to fuel consumption)
Max. 0.15
0.3
Radiator pressure
valve
Opening pressure
(Differential pressure)
kPa
{kg/cm2}
Fan speed
rpm
1,346
mm
Auto-tensioner
114E-3 Series
SEN00261-02
Engine model
SAA6D114E-3
Applicable machine
WA430-6
Prerformance
Item
Unit
Standard value
Permissible value
rpm
2,245 50
2,245 50
rpm
765 25
765 25
Necessary starting
speed
At 0C
rpm
At 20C
rpm
85
Intake resistance
At all speed
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Intake pressure
(Air connector outlet)
At rated horsepower
kPa
{mmHg}
141 181
{1,060 1,360}
107
{800}
Exhaust pressure
(Turbine inlet press.)
At rated horsepower
kPa
{mmHg}
140 180
{1,050 1,350}
113
{850}
Exhaust temperature
(Turbine outlet temp.)
Max. 600
Max. 650
Max. 1.0
Max. 2.0
Max. 25
Max. 35
Engine speed
At rated horsepower
Exhaust gas color
Lubrication system
Engine body
Valve clearance
Cooling system
Condition, etc
Compression pressure
Blow-by pressure
Oil pressure
Quick acceleration
(Low idle o high idle)
Intake valve
mm
0.305
0.152 0.559
Exhaust valve
mm
0.559
0.381 0.813
MPa
{kg/cm2}
Min. 2.6
{Min. 26.5}
2.1
{21.4}
kPa
{mmH2O}
Max. 1.57
{Max. 160}
Max. 2.55
{Max. 260}
At rated horsepower
(Oil temperature: Min. 80C)
SAE15W-40
MPa
{kg/cm2}
0.34 0.59
{3.5 6.0}
0.21
{2.1}
At low idle
(Oil temperature: Min. 80C)
SAE15W-40
MPa
{kg/cm2}
Min. 0.15
{Min. 1.5}
0.08
{0.8}
Oil temperature
At all speed
(Oil in oil pan)
80 110
120
At continuous rated
(Ratio to fuel consumption)
Max. 0.15
0.3
Radiator pressure
valve
Opening pressure
(Differential pressure)
kPa
{kg/cm2}
Fan speed
rpm
(Chassis side)
mm
Auto-tensioner
114E-3 Series
SEN00261-02
Engine model
SAA6D114E-3
Applicable machine
Prerformance
Item
Unit
Standard value
Permissible value
rpm
2,030 50
2,030 50
rpm
825 25
825 25
Necessary starting
speed
At 0C
rpm
At 20C
rpm
80
Intake resistance
At all speed
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Intake pressure
(Air connector outlet)
At rated horsepower
kPa
{mmHg}
129 169
{970 1,270}
94.7
{710}
Exhaust pressure
(Turbine inlet press.)
At rated horsepower
kPa
{mmHg}
117 157
{880 1,180}
90.7
{680}
Exhaust temperature
(Turbine outlet temp.)
Max. 600
Max. 650
Max. 1.0
Max. 2.0
Max. 25
Max. 35
Engine speed
At rated horsepower
Exhaust gas color
Cooling system
Lubrication system
Engine body
Valve clearance
Condition, etc
Compression pressure
Blow-by pressure
Oil pressure
Quick acceleration
(Low idle o high idle)
Intake valve
mm
0.305
0.152 0.559
Exhaust valve
mm
0.559
0.381 0.813
MPa
{kg/cm2}
Min. 2.6
{Min. 26.5}
2.1
{21.4}
kPa
{mmH2O}
Max. 1.57
{Max. 160}
Max. 2.55
{Max. 260}
At rated horsepower
(Oil temperature: Min. 80C)
SAE15W-40
MPa
{kg/cm2}
0.34 0.59
{3.5 6.0}
0.21
{2.1}
At low idle
(Oil temperature: Min. 80C)
SAE15W-40
MPa
{kg/cm2}
Min. 0.15
{Min. 1.5}
0.08
{0.8}
Oil temperature
At all speed
(Oil in oil pan)
80 110
120
At continuous rated
(Ratio to fuel consumption)
Max. 0.15
0.3
Radiator pressure
valve
Opening pressure
(Differential pressure)
kPa
{kg/cm2}
Fan speed
rpm
(Chassis side)
mm
Auto-tensioner
114E-3 Series
SEN00261-02
Engine model
SAA6D114E-3
Applicable machine
GD655-3E0, GD675-3E0
Prerformance
Item
Unit
Standard value
Permissible value
rpm
2,225 50
2,050 50
rpm
825 25
1,000 25
Necessary starting
speed
At 0C
rpm
At 20C
rpm
Intake resistance
At all speed
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Intake pressure
(Air connector outlet)
At rated horsepower
kPa
{mmHg}
135 175
{1,010 1,310}
100
{750}
Exhaust pressure
(Turbine inlet press.)
At rated horsepower
kPa
{mmHg}
127 167
{950 1,250}
100
{750}
Exhaust temperature
(Turbine outlet temp.)
Max. 600
Max. 650
Max. 1.0
Max. 2.0
Max. 25
Max. 35
Engine speed
At rated horsepower
Exhaust gas color
Lubrication system
Engine body
Valve clearance
Cooling system
Condition, etc
Compression pressure
Blow-by pressure
Oil pressure
Quick acceleration
(Low idle o high idle)
Intake valve
mm
0.305
0.152 0.559
Exhaust valve
mm
0.559
0.381 0.813
MPa
{kg/cm2}
Min. 2.6
{Min. 26.5}
2.1
{21.4}
kPa
{mmH2O}
Max. 1.57
{Max. 160}
Max. 2.55
{Max. 260}
At rated horsepower
(Oil temperature: Min. 80C)
SAE15W-40
MPa
{kg/cm2}
0.34 0.59
{3.5 6.0}
0.21
{2.1}
At low idle
(Oil temperature: Min. 80C)
SAE15W-40
MPa
{kg/cm2}
Min. 0.15
{Min. 1.5}
0.08
{0.8}
Oil temperature
At all speed
(Oil in oil pan)
80 110
120
At continuous rated
(Ratio to fuel consumption)
Max. 0.15
0.3
Radiator pressure
valve
Opening pressure
(Differential pressure)
kPa
{kg/cm2}
Fan speed
rpm
(Chassis side)
mm
Auto-tensioner
114E-3 Series
SEN00261-02
Run-in standard
Engine
SAA6D114E-3
Applicable machine
Item
Running time
min
10
10
Engine speed
rpm
1,000
1,000
1,200
1,600
1,950
N {kg}
0 {0}
98 {10}
245 {25}
637 {65}
1,294 {132}
kW {HP}
0 {0}
7.4 {10}
22 {30}
76 {103}
194 {260}
Dynamometer load
Output
a
a
The table gives the standard values for machines without fan.
The loads for the dynamometer are at an arms length of 716 mm.
SAA6D114E-3
PC300, 300LC-7E0, PC350, 350LC-7E0
PC300, 300LC-8, PC350, 350LC-8
Applicable machine
Rated horsepower
Max. torque
High idle
speed
Low idle
speed
2,050 rpm
1,000 rpm
Speed
rpm
1,950
1,450
2,050
1,000
Dynamometer load
N
{kg}
1,294
{132}
1,580
{161}
Output (Gross)
kW
{HP}
194
{260}
Torque (Gross)
Nm
{kgm}
1,129
{115}
Fuel consumption
sec/
300cc
20
Coolant temperature
83 95
83 95
83 95
83 95
Lubricating oil
temperature
80 110
80 110
80 110
80 110
Lubricating oil
pressure
kPa
{kg/cm2}
0.34 0.59
{3.5 6.0}
Min. 0.15
{Min. 1.5}
Max. 700
Max. 750
Test item
Specification value
(Gross)
Exhaust temperature
a
a
a
a
a
This table shows the standard values using the JIS correction factor.
The output and torque values in the table are the standard values with the fan removed, so they are different from the specification values.
This table shows the standard values with an air cleaner installed, muffler installed, alternator under no
load.
The dynamometer load shows the value for an arm length of 716 mm.
Use ASTM D975 diesel oil as the fuel.
Use SAE15W-40 as the lubricating oil.
114E-3 Series
SEN00261-02
Run-in standard
Engine
SAA6D114E-3
Applicable machine
WA430-6
Procedure
Item
Running time
min
10
10
Engine speed
rpm
765
1,000
1,200
1,600
2,100
N {kg}
0 {0}
98 {10}
245 {25}
637 {65}
1,097 {112}
kW {HP}
0 {0}
7.4 {10}
22 {29.5}
76 {102}
173 {232}
Dynamometer load
Output
The loads for the dynamometer are at an arms length of 716 mm.
SAA6D114E-3
Applicable machine
WA430-6
Rated horsepower
Max. torque
High idle
speed
Low idle
speed
2,245 rpm
765 rpm
Speed
rpm
2,100
1,450
2,245
765
Dynamometer load
N
{kg}
1,097
{112}
1,420
{145}
Output (Gross)
kW
{HP}
173
{232}
Torque (Gross)
Nm
{kgm}
1,020
{104}
Fuel consumption
sec/
300cc
22
Coolant temperature
75 94
75 94
75 94
75 94
Lubricating oil
temperature
80 110
80 110
80 110
80 110
Lubricating oil
pressure
kPa
{kg/cm2}
0.34 0.59
{3.5 6.0}
Min. 0.15
{Min. 1.5}
Max. 700
Max. 750
Test item
Specification value
(Gross)
Exhaust temperature
a
a
a
a
a
This table shows the standard values using the JIS correction factor.
This table shows the standard values with an air cleaner installed, muffler installed, alternator under no
load.
The dynamometer load shows the value for an arm length of 716 mm.
Use ASTM D975 diesel oil as the fuel.
Use SAE15W-40 as the lubricating oil.
114E-3 Series
SEN00261-02
Run-in standard
Engine
SAA6D114E-3
Applicable machine
Item
Running time
min
10
10
Engine speed
rpm
825
1,000
1,200
1,600
1,950
N {kg}
0 {0}
98 {10}
245 {25}
637 {65}
1,058 {108}
kW {HP}
0 {0}
7.4 {10}
22 {29.5}
76 {102}
154 {206}
Dynamometer load
Output
The loads for the dynamometer are at an arms length of 716 mm.
SAA6D114E-3
Applicable machine
Max. torque
High idle
speed
Low idle
speed
2,030 rpm
825 rpm
Speed
rpm
1,950
1,450
2,030
825
Dynamometer load
N
{kg}
1,058
{108}
1,410
{144}
Output (Gross)
kW
{HP}
154
{206}
Torque (Gross)
Nm
{kgm}
1,010
{103}
Fuel consumption
sec/
300cc
26
Coolant temperature
75 94
75 94
75 94
75 94
Lubricating oil
temperature
80 110
80 110
80 110
80 110
Lubricating oil
pressure
kPa
{kg/cm2}
0.34 0.59
{3.5 6.0}
Min. 0.15
{Min. 1.5}
Max. 700
Max. 750
Test item
Specification value
(Gross)
Exhaust temperature
a
a
a
a
a
This table shows the standard values using the JIS correction factor.
This table shows the standard values with an air cleaner installed, muffler installed, alternator under no
load.
The dynamometer load shows the value for an arm length of 716 mm.
Use ASTM D975 diesel oil as the fuel.
Use SAE15W-40 as the lubricating oil.
114E-3 Series
SEN00261-02
Run-in standard
Engine
SAA6D114E-3
Applicable machine
GD655-3E0, GD675-3E0
Procedure
Item
Running time
min
10
10
Engine speed
rpm
825
1,000
1,200
1,600
1,900
N {kg}
0 {0}
98 {10}
245 {25}
637 {65}
1,090 {111}
kW {HP}
0 {0}
7.4 {10}
22 {29.5}
76 {102}
154 {206}
Dynamometer load
Output
The loads for the dynamometer are at an arms length of 716 mm.
SAA6D114E-3
Applicable machine
GD655-3E0, GD675-3E0
Rated horsepower
Max. torque
High idle
speed
Low idle
speed
2,225 rpm
825 rpm
Speed
rpm
1,900
1,450
2,225
825
Dynamometer load
N
{kg}
1,090
{111}
1,380
{141}
Output (Gross)
kW
{HP}
154
{206}
Torque (Gross)
Nm
{kgm}
990
{101}
Fuel consumption
sec/
300cc
25
Coolant temperature
75 94
75 94
75 94
75 94
Lubricating oil
temperature
80 110
80 110
80 110
80 110
Lubricating oil
pressure
kPa
{kg/cm2}
0.34 0.59
{3.5 6.0}
Min. 0.15
{Min. 1.5}
Max. 700
Max. 750
Test item
Specification value
(Gross)
Exhaust temperature
a
a
a
a
a
This table shows the standard values using the JIS correction factor.
This table shows the standard values with an air cleaner installed, muffler installed, alternator under no
load.
The dynamometer load shows the value for an arm length of 716 mm.
Use ASTM D975 diesel oil as the fuel.
Use SAE15W-40 as the lubricating oil.
114E-3 Series
SEN00261-02
2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (01)
10
SEN00455-01
ENGINE
1SHOP MANUAL
114E-3 Series
114E-3 Series
SEN00455-01
114E-3 Series
SEN00455-01
A
1
C
Part No.
799-201-2202
799-401-2220
795-799-1131
Commercially
available
795-799-6700
795-502-1590
795-790-6110
6754-11-3130
1
2
Testing compression
D
pressure
3
4
Testing blow-by
E
799-201-1504
pressure
Part name
1
1
1
Clearance gauge
Injector puller
Gauge assembly
Adapter
Gasket
1
1
1
1
Blow-by checker
F 2 799-401-2320 Gauge
6732-81-3170 Adapter
3
6215-81-9710 O-ring
1
1
1
1
6732-81-3170 Adapter
6215-81-9710 O-ring
1
1
3 799-401-2320 Gauge
114E-3 Series
4 795-790-6210
795-790-1500
5
799-201-1201
1
795-790-4800
Testing leakage from
pressure limiter and
2 795-790-6700
H
return rate from
Commercially
3
injector
available
799-601-7400
799-601-7500
799-601-9000
799-601-9300
799-601-7360
799-601-7310
799-601-7070
799-601-4100
799-799-5530
Diagnosis sensor
and harness
799-601-4230
799-601-4130
799-601-4160
799-601-4211
799-601-4220
799-601-4140
799-601-4340
799-601-4260
799-601-4190
Remarks
Q'ty
Hose kit
Adapter
1
1
1
1
1
Measuring cylinder
T-adapter assembly
T-adapter assembly
T-adapter assembly
T-adapter assembly
Adapter
T-adapter
T-adapter
T-adapter assembly
T-adapter
T-adapter
T-adapter
T-adapter
T-adapter
T-adapter
T-adapter
T-adapter
T-adapter
T-adapter
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
AMP040 Connector
AMP040 Connector
DT, HD30 Connector
DRC26-40 (5 pins)
Relay (5 pins)
AWP (12 poles)
AWP (16 poles)
Connected with engine
Engine coolant temperature
Boost temperature/pressure sensor
Ne sensor, CAM sensor
Hydraulic pressure sensor
Controller (50 poles)
Controller (60 poles)
Atmospheric pressure sensor
Pump actuator
Controller (4 poles)
Common rail pressure sensor
SEN00455-01
Part No.
799-201-2202
1.
2.
3.
4.
Symbol
Part name
Boost gauge kit
114E-3 Series
SEN00455-01
Symbol
C
1.
Part No.
Part name
795-799-1131
Gear
Commercially
available
Clearance gauge
2.
2)
3.
4.
114E-3 Series
After placing the No. 1 cylinder at the compression top dead center, place a counter mark on
the damper, and install a pointer to gear cover
(7) using wire.
SEN00455-01
5.
6.
7.
4)
Rotate the crankshaft forward 360, precisely make alignment with the counter
mark placed on Step 4, and adjust the
valve clearance indicated by Q.
a At this moment, the stamp line (b) of
the fuel injection pump gear is aligned
with the stamp line (c) right below.
5)
114E-3 Series
SEN00455-01
5.
6.
Symbol
Part No.
Part name
795-799-6700
Injector puller
795-502-1590
Gauge assembly
795-790-6110
Adapter
6754-11-3130
Gasket
When measuring the compression pressure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
caught in a rotating part.
Measure the compression pressure after the
engine is warmed up.
(Engine oil temperature: 40 60C).
1.
7.
2.
8.
9.
3.
4.
114E-3 Series
SEN00455-01
2)
3)
4)
5)
6)
SEN00455-01
7)
9)
114E-3 Series
SEN00455-01
Symbol
Part No.
799-201-1504
Part name
Blow-by checker
1.
2.
3.
4.
10
114E-3 Series
SEN00455-01
4.
5.
Symbol
Part No.
Part name
799-101-5002
Hydraulic tester
799-401-2320
6732-81-3170
Adapter
(10 x 1.0 mm o R1/8)
6215-81-9710
O-ring
F
3
1.
2.
3.
Connect the hose of hydraulic tester F1 to nipple [1] and gauge F2.
114E-3 Series
11
SEN00455-01
12
Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running.
Low-pressure circuit:
Feed pump Fuel filter Fuel supply
pump
High-pressure circuit:
Fuel supply pump Common rail
Fuel injector
The pressure in both low-pressure circuit and
high-pressure circuit lowers to a safety level
automatically 30 seconds after the engine is
stopped.
Before the fuel circuit is tested and its parts are
removed, the residual pressure in the fuel circuit must be released completely. Accordingly,
observe the following.
Before testing the fuel system or removing
its parts, wait at least 30 seconds after stopping the engine until the residual pressure
in the fuel circuit is released. (Do not start
the work just after stopping the engine
since there is residual pressure.)
114E-3 Series
SEN00455-01
2)
3)
4)
Symbol
Hydraulic tester
790-261-1204
6732-81-3170
Adapter
(10 x 1.0 mm o PT1/8)
6215-81-9710
O-ring
799-401-2320
795-790-6210
2
G
1.
Part name
799-101-5002
Part No.
795-790-1500
799-201-1201
2.
114E-3 Series
13
SEN00455-01
2)
3)
4)
3.
14
2)
3)
4)
114E-3 Series
4.
SEN00455-01
4)
5.
2)
3)
114E-3 Series
2)
3)
15
SEN00455-01
a
4)
6.
3)
2)
16
114E-3 Series
4)
SEN00455-01
114E-3 Series
17
SEN00455-01
No-injection cranking
1.
2.
3.
18
114E-3 Series
SEN00455-01
1.
Symbol
Part No.
Part name
795-790-4800
Hose kit
795-790-6700
Adapter
Commercially
available
Measuring cylinder
2.
2)
3)
4)
5)
6)
Low idle
114E-3 Series
2)
3)
19
SEN00455-01
4)
5)
4)
5)
6)
6)
3.
Low idle
7)
2)
3)
20
Cranking
114E-3 Series
SEN00455-01
3.
4.
1.
5.
6.
2.
114E-3 Series
21
SEN00455-01
Very high pressure is generated in the highpressure circuit of the fuel system. If fuel
leaks while the engine is running, it is dangerous since it can catch fire.
After testing the fuel system or removing
its parts, test it for fuel leakage according
to the following procedure.
Clean and degrease the engine and the parts
around it in advance so that you can test it easily for fuel leakage.
1.
2.
3.
4.
5.
6.
7.
8.
22
9.
114E-3 Series
SEN00455-01
2.
3.
The auto-tensioner is provided for the alternator belt. Thus, testing and adjustment of the
belt is usually no necessary.
Disconnect air conditioner compressor belt
before replacing the alternator belt.
1.
2.
1.
114E-3 Series
23
SEN00455-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 05-07 (01)
24
SEN00457-01
ENGINE
1SHOP MANUAL
114E-3 Series
40 Troubleshooting
114E-3 Series
SEN00457-01
40 Troubleshooting
Points on troubleshooting
k
k
k
k
k
k
Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are
securely fitted.
When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative () terminal of the battery first.
When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to
understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symptoms.
1.
2.
3.
4.
5.
6.
114E-3 Series
40 Troubleshooting
SEN00457-01
INSITE
error code
Machine failure
code
111
CA111
115
CA115
122
CA122
Failure phenomenon
123
CA123
131
CA131
132
CA132
144
CA144
145
CA145
153
CA153
154
CA154
155
CA155
187
CA187
221
CA221
222
CA222
227
CA227
234
CA234
Eng. Overspeed
238
CA238
271
CA271
272
CA272
281
CA281
322
CA322
323
CA323
324
CA324
325
CA325
331
CA331
332
CA332
342
CA342
351
CA351
352
CA352
386
CA386
428
CA428
429
CA429
431
CA431
432
CA432
435
CA435
441
CA441
442
CA442
449
CA449
451
CA451
452
CA452
488
CA488
553
CA553
114E-3 Series
Reference
document No.
Troubleshooting
of electrical
system
(E-mode), Part 1
SEN00459-01
Troubleshooting
of electrical
system
(E-mode), Part 2
SEN00460-01
SEN00457-01
a
a
40 Troubleshooting
INSITE
error code
Machine failure
code
559
CA559
689
CA689
731
CA731
757
CA757
778
CA778
1633
CA1633
KOMNET Error
2185
CA2185
2186
CA2186
2249
CA2249
2265
CA2265
2266
CA2266
Failure phenomenon
2311
CA2311
2555
CA2555
2556
CA2556
B@BAZG
B@BAZG
B@BCNS
Eng. Overheat
Reference
document No.
Troubleshooting
of electrical
system
(E-mode), Part 2
SEN00460-01
114E-3 Series
40 Troubleshooting
114E-3 Series
SEN00457-01
SEN00457-01
40 Troubleshooting
The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
Error code
Failure code
Display on
INSITE
Display on
applicable
machine
Contents of
trouble
Trouble
Action of
controller
Action taken by engine controller to protect system or devices when engine controller detects
trouble
Problem that
appears
on machine
Problem that appears on engine as result of action taken by engine controller (shown above)
Related information
Causes
2
Possible
causes and
standard value
in normal state
114E-3 Series
40 Troubleshooting
SEN00457-01
114E-3 Series
SEN00457-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 05-07 (01)
SEN00459-01
ENGINE
1SHOP MANUAL
114E-3 Series
40 Troubleshooting
114E-3 Series
SEN00459-01
40 Troubleshooting
E-14 Code [222/CA222] Ambient Air Press. Sensor Low Error ......................................................... 26
E-15 Code [227/CA227] Abnormally high level in sensor power supply 2 circuit............................... 28
E-16 Code [234/CA234] Eng. Overspeed .......................................................................................... 29
E-17 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error............................................................... 30
E-18 Code [271/CA271] IMV (IMA) Short Error ................................................................................. 31
E-19 Code [272/CA272] IMV (IMA) Open Error ................................................................................. 32
E-20 Code [281/CA281] High pressure pump error ........................................................................... 34
E-21 Code [322/CA322] Injector No. 1 System Open/Short Error ..................................................... 36
E-22 Code [323/CA323] Injector No. 5 System Open/Short Error ..................................................... 38
E-23 Code [324/CA324] Injector No. 3 System Open/Short Error ..................................................... 40
E-24 Code [325/CA325] Injector No. 6 System Open/Short Error ..................................................... 42
E-25 Code [331/CA331] Injector No. 2 System Open/Short Error ..................................................... 44
E-26 Code [332/CA332] Injector No. 4 System Open/Short Error ..................................................... 46
E-27 Code [342/CA342] Engine Controller Data Matching Error ....................................................... 48
114E-3 Series
40 Troubleshooting
SEN00459-01
Error code
Failure code
111
CA111
Contents of
trouble
Trouble
Action of controller
None in particular.
Problem that
appears on
machine
Related information
Possible causes
and standard
value in normal
state
Causes
Failure code
115
CA115
Contents of
trouble
Trouble
Abnormality occurred in signals of engine Ne speed sensor and engine Bkup speed sensor circuit.
Action of controller
Problem that
appears on
machine
Engine stops
Engine does not start
Related information
Possible causes
and standard
value in normal
state
114E-3 Series
Causes
1
Defective connection of sen- Check Ne speed sensor and Bkup speed sensor directory for defecsor connector
tive connection (wrong connection).
SEN00459-01
40 Troubleshooting
Failure code
122
CA122
Contents of
trouble
Trouble
High voltage is detected in pressure signal circuit of boost pressure sensor and temperature sensor.
Action of controller
Fixes charge pressure (101 kPa {1.03 kg/cm2}) and continues operation.
Problem that
appears on
machine
Related information
Causes
1
Defective sensor power sup- If failure code [CA227] is indicated simultaneously, carry out troubleply 2 system
shooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Possible causes
and standard
value in normal
state
4.75 5.25 V
a Troubleshoot with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between J1 (female) (44)
BOOST PRESS & IMT (female) (1) and
between J1 (female) (37) BOOST PRESS
& IMT (female) (2)
Resistance
Min.
100 kz
Connecting parts among boost pressure sensor, temperature sensor, engine wiring harness, and engine controller are suspected.
Inspect them directly.
Loose connector, broken lock, broken seal
Corrosive, bent, broken, forced-in, or extended pin
Humidity in connector, entry of dirt or dust, poor insulation
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
J1
Between (37) (47)
Power supply
Voltage
Voltage
Power supply
4.75 5.25 V
114E-3 Series
40 Troubleshooting
SEN00459-01
114E-3 Series
SEN00459-01
40 Troubleshooting
Failure code
123
CA123
Contents of
trouble
Trouble
Low voltage is detected in pressure signal circuit of boost pressure sensor and temperature sensor.
Action of controller
Fixes charge pressure (101 kPa {1.03 kg/cm2}) and continues operation.
Problem that
appears on
machine
Related information
Causes
1
Defective sensor power sup- If failure code [CA187] is indicated simultaneously, carry out troubleply 2 system
shooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Possible causes
and standard
value in normal
state
4.75 5.25 V
Resistance
Min.
100 kz
Connecting parts among boost pressure sensor, temperature sensor, engine wiring harness, and engine controller are suspected.
Inspect them directly.
Loose connector, broken lock, broken seal
Corrosive, bent, broken, forced-in, or extended pin
Humidity in connector, entry of dirt or dust, poor insulation
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
J1
Between (37) (47)
Power supply
Voltage
Voltage
Power supply
4.75 5.25 V
114E-3 Series
40 Troubleshooting
SEN00459-01
114E-3 Series
SEN00459-01
40 Troubleshooting
Failure code
131
CA131
Contents of
trouble
Trouble
Action of controller
Problem that
appears on
machine
Related information
Causes
If failure code [CA2185] is indicated simultaneously, carry out troubleshooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
P20
Voltage
Power supply
4.75 5.25 V
Possible causes
and standard
value in normal
state
Min.
100 kz
Connecting parts among fuel control dial, engine unit wiring harness, and engine controller are suspected. Inspect them directly.
Loose connector, broken lock, broken seal
Corrosive, bent, broken, forced-in, or extended pin
Humidity in connector, entry of dirt or dust, poor insulation
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
J2
Between (22) (23)
Resistance
Voltage
Power supply
4.75 5.25 V
114E-3 Series
40 Troubleshooting
SEN00459-01
114E-3 Series
SEN00459-01
40 Troubleshooting
Failure code
132
CA132
Contents of
trouble
Trouble
Action of controller
Problem that
appears on
machine
Related information
Causes
If failure code [CA2186] is indicated simultaneously, carry out troubleshooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
P20
Voltage
Power supply
4.75 5.25 V
Possible causes
and standard
value in normal
state
Min.
100 kz
Connecting parts among fuel control dial, engine unit wiring harness, and engine controller are suspected. Inspect them directly.
Loose connector, broken lock, broken seal
Corrosive, bent, broken, forced-in, or extended pin
Humidity in connector, entry of dirt or dust, poor insulation
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
J2
Between (22) (23)
10
Resistance
Voltage
Power supply
4.75 5.25 V
114E-3 Series
40 Troubleshooting
SEN00459-01
114E-3 Series
11
SEN00459-01
40 Troubleshooting
Failure code
144
CA144
Contents of
trouble
Trouble
Action of controller
Problem that
appears on
machine
Related information
Causes
Possible causes
and standard
value in normal
state
Coolant temperature
Resistance
0C
30 37 kz
25C
9.3 10.7 kz
50C
3.2 3.8 kz
80C
1.0 1.3 kz
95C
700 800 z
Resistance
Min.
100 kz
12
Coolant temperature
Resistance
0C
30 37 kz
25C
9.3 10.7 kz
50C
3.2 3.8 kz
80C
1.0 1.3 kz
95C
700 800 z
114E-3 Series
40 Troubleshooting
SEN00459-01
114E-3 Series
13
SEN00459-01
40 Troubleshooting
Failure code
145
CA145
Contents of
trouble
Trouble
Action of controller
Problem that
appears on
machine
Related information
Causes
Between (B)
chassis ground
Coolant temperature
Resistance
0C
30 37 kz
25C
9.3 10.7 kz
50C
3.2 3.8 kz
80C
1.0 1.3 kz
95C
700 800 z
All range
Min. 100 kz
Resistance
Min.
100 kz
Between (15)
chassis ground
14
Coolant temperature
Resistance
0C
30 37 kz
25C
9.3 10.7 kz
50C
3.2 3.8 kz
80C
1.0 1.3 kz
95C
700 800 z
All range
Min. 100 kz
114E-3 Series
40 Troubleshooting
SEN00459-01
114E-3 Series
15
SEN00459-01
40 Troubleshooting
Failure code
153
CA153
Contents of
trouble
Trouble
High voltage is detected in temperature signal circuit of boost pressure sensor and temperature sensor.
Action of controller
Problem that
appears on
machine
Related information
Causes
Charge temperature
Resistance
0C
29 36 kz
25C
9 11 kz
40C
4.9 5.8 kz
100C
600 700 z
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between J1 (female) (23)
2
or defective contact in con- BOOST PRESS & IMT (female) (3)
nector)
Wiring harness between J1 (female) (47)
BOOST PRESS & IMT (female) (4)
Short circuit in wiring har3 ness (With another wiring
harness)
Resistance
Max. 10 z
Resistance
Max. 10 z
Resistance
Min.
100 kz
Connecting parts among boost pressure sensor, temperature sensor, engine wiring harness, and engine controller are suspected.
Inspect them directly.
Loose connector, broken lock, broken seal
Corrosive, bent, broken, forced-in, or extended pin
Humidity in connector, entry of dirt or dust, poor insulation
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
J1 (female)
16
Charge temperature
Resistance
0C
29 36 kz
25C
9 11 kz
40C
4.9 5.8 kz
100C
600 700 z
114E-3 Series
40 Troubleshooting
SEN00459-01
114E-3 Series
17
SEN00459-01
40 Troubleshooting
Failure code
154
CA154
Contents of
trouble
Trouble
Low voltage is detected in temperature signal circuit of boost pressure sensor and temperature sensor.
Action of controller
Problem that
appears on
machine
Related information
Causes
Between (3)
chassis ground
Charge temperature
Resistance
0C
29 36 kz
25C
9 11 kz
40C
4.9 5.8 kz
100C
600 700 z
All range
Min. 100 kz
Resistance
Min.
100 kz
Connecting parts among boost pressure sensor, temperature sensor, engine wiring harness, and engine controller are suspected.
Inspect them directly.
Loose connector, broken lock, broken seal
Corrosive, bent, broken, forced-in, or extended pin
Humidity in connector, entry of dirt or dust, poor insulation
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
J1 (female)
Between (23)
chassis ground
18
Charge temperature
Resistance
0C
29 36 kz
25C
9 11 kz
40C
4.9 5.8 kz
100C
600 700 z
All range
Min. 100 kz
114E-3 Series
40 Troubleshooting
SEN00459-01
114E-3 Series
19
SEN00459-01
40 Troubleshooting
Failure code
155
CA155
Contents of
trouble
Trouble
Temperature signal of boost pressure sensor and temperature sensor is above upper control limit.
Action of controller
Problem that
appears on
machine
Engine stops
Output drops.
Related information
Causes
Possible causes
and standard
value in normal
state
20
114E-3 Series
40 Troubleshooting
114E-3 Series
SEN00459-01
21
SEN00459-01
40 Troubleshooting
Failure code
187
CA187
Contents of
trouble
Trouble
Action of controller
Problem that
appears on
machine
Related information
Causes
Possible causes
and standard
value in normal
state
22
114E-3 Series
40 Troubleshooting
SEN00459-01
114E-3 Series
23
SEN00459-01
40 Troubleshooting
Failure code
221
CA221
Contents of
trouble
Trouble
Action of controller
Problem that
appears on
machine
Related information
Causes
1
Defective sensor power sup- If failure code [CA386] is indicated simultaneously, carry out troubleply 1 system
shooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
AMBAIR PRESSURE
Between (1) (2)
Power supply
Voltage
4.75 5.25 V
Possible causes
and standard
value in normal
state
Min.
100 kz
Connecting parts among atmospheric pressure sensor, engine wiring harness, and engine controller are suspected. Inspect them
directly.
Loose connector, broken lock, broken seal
Corrosive, bent, broken, forced-in, or extended pin
Humidity in connector, entry of dirt or dust, poor insulation
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
J1
Between (33) (38)
24
Resistance
Voltage
Power supply
4.75 5.25 V
114E-3 Series
40 Troubleshooting
SEN00459-01
114E-3 Series
25
SEN00459-01
40 Troubleshooting
Failure code
222
CA222
Contents of
trouble
Trouble
Action of controller
Problem that
appears on
machine
Related information
Causes
1
Defective sensor power sup- If failure code [CA352] is indicated simultaneously, carry out troubleply 1 system
shooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
AMBAIR PRESSURE
Between (1) (2)
Power supply
Voltage
4.75 5.25 V
Possible causes
and standard
value in normal
state
Min.
100 kz
Connecting parts among atmospheric pressure sensor, engine wiring harness, and engine controller are suspected. Inspect them
directly.
Loose connector, broken lock, broken seal
Corrosive, bent, broken, forced-in, or extended pin
Humidity in connector, entry of dirt or dust, poor insulation
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
J1
Between (33) (38)
26
Resistance
Voltage
Power supply
4.75 5.25 V
114E-3 Series
40 Troubleshooting
SEN00459-01
114E-3 Series
27
SEN00459-01
40 Troubleshooting
Failure code
227
CA227
Contents of
trouble
Trouble
Action of controller
Problem that
appears on
machine
Related information
Causes
Possible causes
and standard
value in normal
state
28
114E-3 Series
40 Troubleshooting
SEN00459-01
Failure code
234
CA234
Contents of
trouble
Trouble
Engine overspeed
Action of controller
Problem that
appears on
machine
Related information
Method of reproducing failure code: Start engine and run it at high idle.
Causes
Possible causes
and standard
value in normal
state
114E-3 Series
If causes 1 and 2 is not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried
out.)
29
SEN00459-01
40 Troubleshooting
Failure code
238
CA238
Contents of
trouble
Action of
controller
Trouble
Problem that
appears
on machine
Related information
Causes
Possible
causes and
standard value
in normal state
Disconnect devices at
right in order.
If mark E of failure
code disappears after
reproduction operation is conducted, that
device or wiring
harness has a
defect in it.
Ne speed sensor
CRANK SENSOR
Engine wiring
harness
J1
30
114E-3 Series
40 Troubleshooting
SEN00459-01
Failure code
271
CA271
Contents of
trouble
Action of
controller
Trouble
Problem that
appears
on machine
Related information
Causes
Min. 100 kz
Resistance
Min.
100 kz
Connecting parts among supply pump actuator, engine wiring harness, and engine controller are suspected. Inspect them directly.
Loose connector, broken lock, broken seal
Corrosive, bent, broken, forced-in, or extended pin
Humidity in connector, entry of dirt or dust, poor insulation
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
J1 (Female)
Resistance
Min. 100 kz
114E-3 Series
31
SEN00459-01
40 Troubleshooting
Failure code
272
CA272
Contents of
trouble
Action of
controller
Trouble
Problem that
appears
on machine
Related information
Causes
Max. 5 z
Disconnection in wiring harness (Disconnection in wiring Wiring harness between J1 (female) (2)
2
or defective contact in con- CP3 PUMP REGULATOR (female) (1)
nector)
Wiring harness between J1 (female) (32)
CP3 PUMP REGULATOR (female) (2)
Possible
causes and
standard value
in normal state
Max. 10 z
Resistance
Max. 10 z
32
Resistance
Resistance
Min.
100 kz
Connecting parts among supply pump actuator, engine wiring harness, and engine controller are suspected.
Inspect them directly.
Loose connector, broken lock, broken seal
Corrosive, bent, broken, forced-in, or extended pin
Humidity in connector, entry of dirt or dust, poor insulation
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
J1 (Female)
Resistance
Max. 5 z
114E-3 Series
40 Troubleshooting
SEN00459-01
114E-3 Series
33
SEN00459-01
40 Troubleshooting
Failure code
281
CA281
Contents of
trouble
Trouble
Response of fuel force feed is poor due to high pressure pump mechanical system error.
Action of controller
None in particular.
Problem that
appears on
machine
Related information
Causes
1 Air in fuel circuit
Possible causes
and standard
value in normal
state
34
Connecting parts among common rail pressure sensor, engine wiring harness, and engine controller are suspected. Inspect them
directly.
Loose connector, broken lock, broken seal
Corrosive, bent, broken, forced-in, or extended pin
Humidity in connector, entry of dirt or dust, poor insulation
If causes 1 and 2 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried
out.)
114E-3 Series
40 Troubleshooting
114E-3 Series
SEN00459-01
35
SEN00459-01
40 Troubleshooting
Failure code
322
CA322
Contents of
trouble
Trouble
Resistance
Max. 2 z
Min. 100 kz
Disconnection in wiring harness (Disconnection in wiring Wiring harness between J1 (female) (45)
2
or defective contact in con- INJ CYL 1 & 2 (female) (3)
nector)
Wiring harness between J1 (female) (53)
INJ CYL 1 & 2 (female) (4)
Resistance
Max. 2 z
Resistance
Max. 2 z
Resistance
Min.
100 kz
Resistance
Min.
100 kz
If any other failure codes related to injector are displayed, carry out
troubleshooting for them first.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
36
J1 (female)
Resistance
Max. 2 z
Min. 100 kz
114E-3 Series
40 Troubleshooting
SEN00459-01
114E-3 Series
37
SEN00459-01
40 Troubleshooting
Failure code
323
CA323
Contents of
trouble
Trouble
Resistance
Max. 2 z
Min. 100 kz
Disconnection in wiring harness (Disconnection in wiring Wiring harness between J1 (female) (46)
2
or defective contact in con- INJ CYL 5 & 6 (female) (3)
nector)
Wiring harness between J1 (female) (60)
INJ CYL 5 & 6 (female) (4)
Resistance
Max. 2 z
Resistance
Max. 2 z
Resistance
Min.
100 kz
Resistance
Min.
100 kz
If any other failure codes related to injector are displayed, carry out
troubleshooting for them first.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
38
J1 (female)
Resistance
Max. 2 z
Min. 100 kz
114E-3 Series
40 Troubleshooting
SEN00459-01
114E-3 Series
39
SEN00459-01
40 Troubleshooting
Failure code
324
CA324
Contents of
trouble
Trouble
Resistance
Max. 2 z
Min. 100 kz
Disconnection in wiring harness (Disconnection in wiring Wiring harness between J1 (female) (55)
2
or defective contact in con- INJ CYL 3 & 4 (female) (3)
nector)
Wiring harness between J1 (female) (52)
INJ CYL 3 & 4 (female) (4)
Resistance
Max. 2 z
Resistance
Max. 2 z
Resistance
Min.
100 kz
Resistance
Min.
100 kz
If any other failure codes related to injector are displayed, carry out
troubleshooting for them first.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
40
J1 (female)
Resistance
Max. 2 z
Min. 100 kz
114E-3 Series
40 Troubleshooting
SEN00459-01
114E-3 Series
41
SEN00459-01
40 Troubleshooting
Failure code
325
CA325
Contents of
trouble
Trouble
Resistance
Max. 2 z
Min. 100 kz
Disconnection in wiring harness (Disconnection in wiring Wiring harness between J1 (female) (57)
2
or defective contact in con- INJ CYL 5 & 6 (female) (2)
nector)
Wiring harness between J1 (female) (59)
INJ CYL 5 & 6 (female) (1)
Resistance
Max. 2 z
Resistance
Max. 2 z
Resistance
Min.
100 kz
Resistance
Min.
100 kz
If any other failure codes related to injector are displayed, carry out
troubleshooting for them first.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
42
J1 (female)
Resistance
Max. 2 z
Min. 100 kz
114E-3 Series
40 Troubleshooting
SEN00459-01
114E-3 Series
43
SEN00459-01
40 Troubleshooting
Failure code
331
CA331
Contents of
trouble
Trouble
Resistance
Max. 2 z
Min. 100 kz
Disconnection in wiring harness (Disconnection in wiring Wiring harness between J1 (female) (54)
2
or defective contact in con- INJ CYL 1 & 2 (female) (2)
nector)
Wiring harness between J1 (female) (51)
INJ CYL 1 & 2 (female) (1)
Resistance
Max. 2 z
Resistance
Max. 2 z
Resistance
Min.
100 kz
Resistance
Min.
100 kz
If any other failure codes related to injector are displayed, carry out
troubleshooting for them first.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
44
J1 (female)
Resistance
Max. 2 z
Min. 100 kz
114E-3 Series
40 Troubleshooting
SEN00459-01
114E-3 Series
45
SEN00459-01
40 Troubleshooting
Failure code
332
CA332
Contents of
trouble
Trouble
Resistance
Max. 2 z
Min. 100 kz
Disconnection in wiring harness (Disconnection in wiring Wiring harness between J1 (female) (56)
2
or defective contact in con- INJ CYL 3 & 4 (female) (2)
nector)
Wiring harness between J1 (female) (58)
INJ CYL 3 & 4 (female) (1)
Resistance
Max. 2 z
Resistance
Max. 2 z
Resistance
Min.
100 kz
Resistance
Min.
100 kz
If any other failure codes related to injector are displayed, carry out
troubleshooting for them first.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
46
J1 (female)
Resistance
Max. 2 z
Min. 100 kz
114E-3 Series
40 Troubleshooting
SEN00459-01
114E-3 Series
47
SEN00459-01
40 Troubleshooting
Failure code
342
CA342
Contents of
trouble
Action of
controller
Trouble
Problem that
appears
on machine
Related information
Possible
causes and
standard value
in normal state
48
Causes
114E-3 Series
40 Troubleshooting
114E-3 Series
SEN00459-01
49
SEN00459-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 05-07 (01)
50
SEN00460-01
ENGINE
1SHOP MANUAL
114E-3 Series
40 Troubleshooting
114E-3 Series
SEN00460-01
40 Troubleshooting
E-41 Code [488/CA488] Charge Air Temp. High Torque Derate ........................................................ 28
E-42 Code [553/CA553] Rail Press. High Error 1 .............................................................................. 29
E-43 Code [559/CA559] Rail Press Low Error ................................................................................... 30
E-44 Code [689/CA689] Eng. Ne Speed Sensor Error....................................................................... 32
E-45 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error........................................................ 34
E-46 Code [757/CA757] All Engine Controller Data Lost Error .......................................................... 36
E-47 Code [778/CA778] Eng. Bkup Speed Sensor Error ................................................................... 38
E-48 Code [1633/CA1633] KOMNET Error........................................................................................ 40
E-49 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error ........................................................ 42
E-50 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error......................................................... 43
E-51 Code [2249/CA2249] Rail Press very Low Error ....................................................................... 44
E-52 Code [2265/CA2265] Abnormally high level in electric lift pump ............................................... 46
E-53 Code [2266/CA2266] Abnormally low level in electric lift pump................................................. 48
E-54 Code [2311/CA2311] IMV (IMA) Solenoid Error......................................................................... 50
E-55 Code [2555/CA2555] Intake Air Heater Relay Supply Voltage Low Error ................................. 52
E-56 Code [2556/CA2556] Intake Air Heater Relay Supply Voltage High Error................................. 54
E-57 Code [---/B@BAZG] Eng. Oil Press. Low Speed Derate ........................................................... 56
E-58 Code [---/B@BAZG] Eng. Oil Press Low Torque Derate ........................................................... 56
E-59 Code [---/B@BCNS] Eng. Overheat .......................................................................................... 57
114E-3 Series
40 Troubleshooting
SEN00460-01
Error code
Failure code
351
CA351
Contents of
trouble
Action of
controller
Trouble
Problem that
appears
on machine
Related information
Causes
3
Possible
causes and
standard value
in normal state
114E-3 Series
Resistance
Max.
0.5 z
Resistance
Max.
0.5 z
Resistance
Max. 10 z
SEN00460-01
40 Troubleshooting
114E-3 Series
40 Troubleshooting
SEN00460-01
Failure code
352
CA352
Contents of
trouble
Action of
controller
Trouble
Problem that
appears
on machine
Related information
Causes
AMBAIR PRESSURE
Engine wiring
harness
J1
Connecting parts among atmospheric pressure sensor, engine wiring harness, and engine controller are suspected. Inspect them
directly.
Loose connector, broken lock, broken seal
Corrosive, bent, broken, forced-in, or extended pin
Humidity in connector, entry of dirt or dust, poor insulation
If causes 1 and 2 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried
out.)
114E-3 Series
Disconnect devices at
right in order. If mark
E of failure code disappears after reproduction operation is
conducted, that
device or wiring
harness has a
defect in it.
SEN00460-01
40 Troubleshooting
114E-3 Series
40 Troubleshooting
SEN00460-01
Failure code
386
CA386
Contents of
trouble
Action of
controller
Trouble
Problem that
appears
on machine
Related information
Possible
causes and
standard value
in normal state
Causes
Connecting parts among atmospheric pressure sensor, engine wiring harness, and engine controller are suspected. Inspect them
directly.
Loose connector, broken lock, broken seal
Corrosive, bent, broken, forced-in, or extended pin
Humidity in connector, entry of dirt or dust, poor insulation
114E-3 Series
SEN00460-01
40 Troubleshooting
Failure code
428
CA428
Contents of
trouble
Trouble
Action of controller
None in particular.
Problem that
appears on
machine
Related information
Causes
Defective water-in-fuel sen1
sor
Resistance
Max. 10 z
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between J1 (female) (14)
2
or defective contact in con- P47 (male) (1)
nector)
Wiring harness between J1 (female) (47)
P47 (male) (2)
Short circuit in wiring har3 ness (With another wiring
harness)
Resistance
Max. 10 z
Resistance
Max. 10 z
Resistance
Min.
100 kz
Connecting parts among water-in-fuel sensor, engine wiring harness, and engine controller are suspected. Inspect them directly.
Loose connector, broken lock, broken seal
Corrosive, bent, broken, forced-in, or extended pin
Humidity in connector, entry of dirt or dust, poor insulation
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
J1 (female)
Resistance
Max. 10 z
114E-3 Series
40 Troubleshooting
SEN00460-01
114E-3 Series
SEN00460-01
40 Troubleshooting
Failure code
429
CA429
Contents of
trouble
Trouble
Action of controller
None in particular.
Problem that
appears on
machine
Related information
Causes
P47 (female)
Resistance
Max. 10 z
Min. 100 kz
Resistance
Min.
100 kz
Connecting parts among water-in-fuel sensor, engine wiring harness, and engine controller are suspected. Inspect them directly.
Loose connector, broken lock, broken seal
Corrosive, bent, broken, forced-in, or extended pin
Humidity in connector, entry of dirt or dust, poor insulation
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
10
J1 (female)
Resistance
Max. 10 z
Min. 100 kz
114E-3 Series
40 Troubleshooting
SEN00460-01
114E-3 Series
11
SEN00460-01
40 Troubleshooting
controller
Problem that
appears
on machine
Related informa
tion
Failure code
CA431
Possible
causes and
standard value
in normal state
12
114E-3 Series
40 Troubleshooting
SEN00460-01
114E-3 Series
13
SEN00460-01
40 Troubleshooting
Failure code
432
CA432
Contents of
trouble
Action of
controller
Trouble
Problem that
appears
on machine
Related information
Causes
WAS1 (Male)
Between (2) (1)
Accelerator pedal
Resistance
Release
1.5 3.0 kz
Press
0.25 1.5 kz
Resistance
Min.
100 kz
Resistance
Min.
100 kz
Connecting parts among accelerator pedal, engine unit wiring harness, and engine controller are suspected. Inspect them directly.
Loose connector, broken lock, broken seal
Corrosive, bent, broken, forced-in, or extended pin
Humidity in connector, entry of dirt or dust, poor insulation
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
J2 (Female)
Between (22) (9)
14
Accelerator pedal
Resistance
Release
1.5 3.0 kz
Press
0.25 1.5 kz
114E-3 Series
40 Troubleshooting
SEN00460-01
114E-3 Series
15
SEN00460-01
40 Troubleshooting
Failure code
435
CA435
Contents of
trouble
Trouble
Action of controller
None in particular.
Problem that
appears on
machine
Engine oil pressure switch-based engine protection function does not function.
Related information
Causes
Max. 10 z
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
ness (Disconnection in wiring
2
or defective contact in con- Wiring harness between J1 (female) (17)
ResisMax. 10 z
nector)
OIL PRESSURE SWITCH (female) (1)
tance
Possible causes
and standard
value in normal
state
Resistance
Min.
100 kz
Resistance
Max. 10 z
16
114E-3 Series
40 Troubleshooting
114E-3 Series
SEN00460-01
17
SEN00460-01
40 Troubleshooting
controller
Problem that
appears
on machine
Related informa
tion
Failure code
CA441
5
Possible
causes and
standard value
in normal state
6
18
a Prepare with starting switch OFF, then turn starting switch OFF
and START and carry out troubleshooting.
Battery (1 piece)
Starting switch
Voltage
Defective battery voltage
OFF
Min.
12 V
Between (+) ()
terminals
START
Min. 6.2 V
Defective fuse No. 19
If fuse is burnt out, circuit probably has ground fault. (See cause 6.)
a Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective relay for engine
Replace
relays for engine controller power supply (R23, R24) with
controller power supply
other relays. If mark E of failure code disappears after reproduction
operation is conducted, that relay has a defect.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
ResisDisconnection in wiring har- Wiring harness between F01-19 R23, R24
Max. 10 z
tance
ness (Disconnection in wiring (female) (3)
or defective contact in con- Wiring harness between R23, R24 (female)
ResisMax. 10 z
nector)
(5) J3 (female) (3)
tance
Wiring harness between J3 (female) (1)
ResisMax. 10 z
chassis ground (T12)
tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Ground fault in wiring harWiring harness between F01-19 R23, R24
ResisMin.
ness (Short circuit with GND
(female) (3) and chassis ground
tance
100 kz
circuit)
Wiring harness between R23, R24 (female)
ResisMax. 10 z
(5) J3 (female) (3) and chassis ground
tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness among all pins between J3
ResisMin.
(female) (3) J3 (female) (1) (With battery
tance
100 kz
terminal disconnected)
Short circuit in wiring harness
(With another wiring harness) Wiring harness among all pins between J3
ResisMin.
(female) (3) J2 (female) (With battery termitance
100 kz
nal disconnected)
Wiring harness among all pins between J3
ResisMin.
(female) (1) J2 (female) (With battery termitance
100 kz
nal disconnected)
Connecting parts among fuse No. 19, engine unit wiring harness,
and engine controller are suspected. Inspect them directly.
Defective wiring harness con Loose connector, broken lock, broken seal
nector
Corrosive, bent, broken, forced-in, or extended pin
Humidity in connector, entry of dirt or dust, poor insulation
114E-3 Series
40 Troubleshooting
SEN00460-01
Causes
Possible
causes and
standard value
in normal state
114E-3 Series
19
SEN00460-01
40 Troubleshooting
Failure code
442
CA442
Contents of
trouble
Trouble
Action of
controller
None in particular.
Problem that
appears
on machine
Related information
Causes
Possible
causes and
standard value
in normal state
Voltage
Max. 32 V
a Prepare with starting switch OFF, then start the engine and carry
out troubleshooting.
2 Defective alternator
20
E12 (Male)
Engine speed
Voltage
Between (1)
chassis ground
27.5 29.5 V
Voltage
Max. 32 V
114E-3 Series
40 Troubleshooting
SEN00460-01
114E-3 Series
21
SEN00460-01
40 Troubleshooting
Failure code
CA449
Possible causes
and standard
value in normal
state
22
114E-3 Series
40 Troubleshooting
Causes
Defective O-ring of supply
6
pump actuator
7
Possible causes
and standard
value in normal
state
9
10
SEN00460-01
Circuit diagram related to common rail pressure sensor and engine controller GND line
114E-3 Series
23
SEN00460-01
40 Troubleshooting
Failure code
451
CA451
Contents of
trouble
Trouble
Action of controller
Problem that
appears on
machine
Related information
Causes
1
Defective sensor power sup- If failure code [CA227] is indicated simultaneously, carry out troubleply 2 system
shooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Power supply
Voltage
4.75 5.25 V
Possible causes
and standard
value in normal
state
a Troubleshoot with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between J1 (female) (25)
FUEL RAIL PRESS (female) (2) and J1
(female) (37) FUEL RAIL PRESS (female)
(3)
Min.
100 kz
Connecting parts among common rail pressure sensor, engine wiring harness, and engine controller are suspected. Inspect them
directly.
Loose connector, broken lock, broken seal
Corrosive, bent, broken, forced-in, or extended pin
Humidity in connector, entry of dirt or dust, poor insulation
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
J1
Between (37) (47)
24
Resistance
Voltage
Power supply
4.75 5.25 V
114E-3 Series
40 Troubleshooting
SEN00460-01
114E-3 Series
25
SEN00460-01
40 Troubleshooting
Failure code
452
CA452
Contents of
trouble
Trouble
Action of controller
Problem that
appears on
machine
Related information
Causes
1
Defective sensor power sup- If failure code [CA187] is indicated simultaneously, carry out troubleply 2 system
shooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Power supply
Voltage
4.75 5.25 V
Possible causes
and standard
value in normal
state
Min.
100 kz
Connecting parts among common rail pressure sensor, engine wiring harness, and engine controller are suspected. Inspect them
directly.
Loose connector, broken lock, broken seal
Corrosive, bent, broken, forced-in, or extended pin
Humidity in connector, entry of dirt or dust, poor insulation
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
J1
Between (37) (47)
26
Resistance
Voltage
Power supply
4.75 5.25 V
114E-3 Series
40 Troubleshooting
SEN00460-01
114E-3 Series
27
SEN00460-01
40 Troubleshooting
Failure code
488
CA488
Contents of
trouble
Trouble
Temperature signal of boost pressure sensor and temperature sensor is above upper control limit.
Action of controller
Problem that
appears on
machine
Output drops.
Related information
Causes
Possible causes
and standard
value in normal
state
28
114E-3 Series
40 Troubleshooting
SEN00460-01
Failure code
553
CA553
Contents of
trouble
Trouble
Action of controller
None in particular.
Problem that
appears on
machine
Related information
Causes
1 Defective related system
Possible causes
and standard
value in normal
state
114E-3 Series
Defective connection of
ground terminal
29
SEN00460-01
40 Troubleshooting
Failure code
559
CA559
Contents of
trouble
Trouble
Cranking
Possible causes
and standard
value in normal
state
At high idle
At high idle
At high idle
At high idle
a For testing of return rate from injector, see Testing and adjusting,
Testing leakage from pressure limiter and return rate from injector.
3
30
Cranking (When
engine cannot be
started)
114E-3 Series
40 Troubleshooting
SEN00460-01
Causes
Possible causes
and standard
value in normal
state
114E-3 Series
Cranking (When
engine cannot be
started)
At low idle
Below 30 drops/
60 sec.
31
SEN00460-01
40 Troubleshooting
controller
Problem that
appears
on machine
Related informa
tion
Failure code
CA689
3
4
Possible
causes and
standard value
in normal state
32
Broken engine Ne speed senInspect engine Ne speed sensor for breakage or clearance.
sor or defective clearance
Broken rotation sensing flyInspect it for breakage directly.
wheel
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
ness (Disconnection in wiring
or defective contact in con- Wiring harness between J1 (female) (27)
ResisMax. 10 z
nector)
CRANK SENSOR (female) (3)
tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Ground fault in wiring harness (Short circuit with GND Wiring harness between J1 (female) (27)
ResisMin.
circuit)
CRANK SENSOR (female) (3) and chassis
tance
100 kz
ground
a Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Hot short (Short circuit with
5V, 24V circuit) in wiring har- Wiring harness between J1 (female) (27)
ness
CRANK SENSOR (female) (3) and chassis
Voltage Max. 1 V
ground
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between J1 (female) (27)
Min.
CRANK SENSOR (female) (3) and J1
ResisShort circuit in wiring harness (female) (16) CRANK SENSOR (female)
tance
100 kz
(With another wiring harness) (1)
Wiring harness between J1 (female) (27)
CRANK SENSOR (female) (3) and J1
ResisMin.
(female) (48) CRANK SENSOR (female)
tance
100 kz
(2)
Connecting parts among engine Ne speed sensor, engine wiring
harness, and engine controller are suspected. Inspect them directly.
Defective wiring harness con Loose connector, broken lock, broken seal
nector
Corrosive, bent, broken, forced-in, or extended pin
Humidity in connector, entry of dirt or dust, poor insulation
114E-3 Series
40 Troubleshooting
Possible
causes and
standard value
in normal state
SEN00460-01
Causes
10 Defective engine controller
114E-3 Series
33
SEN00460-01
40 Troubleshooting
Failure code
731
CA731
Contents of
trouble
Action of
controller
Trouble
Abnormal phase is detected in signals of engine Ne speed sensor and engine Bkup speed sensor.
Controls with signals of engine Ne speed sensor.
Problem that
appears
on machine
Related information
Causes
Possible
causes and
standard value
in normal state
34
Defective connection of
ground terminal
114E-3 Series
40 Troubleshooting
114E-3 Series
SEN00460-01
35
SEN00460-01
40 Troubleshooting
Failure code
757
CA757
Contents of
trouble
Trouble
Action of controller
None in particular.
Problem that
appears on
machine
Related information
Causes
5
Possible causes
and standard
value in normal
state
Battery (1 piece)
Starting switch
Voltage
Between (+) ()
terminals
OFF
Min. 12 V
START
Min. 6.2 V
Resistance
Max. 10 z
Resistance
Max. 10 z
Resistance
Max. 10 z
Connecting parts among fuse No. 19, engine unit wiring harness,
and engine controller are suspected. Inspect them directly.
Loose connector, broken lock, broken seal
Corrosive, bent, broken, forced-in, or extended pin
Humidity in connector, entry of dirt or dust, poor insulation
a Prepare with starting switch OFF, then turn starting switch ON
and START and carry out troubleshooting.
J3 (female)
Between (3) (1)
36
Starting switch
Voltage
ON
Min. 24 V
START
Min. 12 V
114E-3 Series
40 Troubleshooting
SEN00460-01
114E-3 Series
37
SEN00460-01
40 Troubleshooting
Failure code
778
CA778
Contents of
trouble
Trouble
Defective sensor power sup- If failure code [CA187] is indicated simultaneously, carry out trouble1
ply 2 system
shooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
2
CAM SENSOR
Between (1) (2)
Power supply
Voltage
4.75 5.25 V
Broken engine Bkup speed Inspect engine Bkup speed sensor directly for breakage or clearsensor or defective clearance ance.
Possible causes
and standard
value in normal
state
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
ness (Disconnection in wiring
5
or defective contact in con- Wiring harness between J1 (female) (26)
ResisMax. 10 z
nector)
CAM SENSOR (female) (3)
tance
a Prepare with starting switch OFF, then carry out troubleshooting
Ground fault in wiring harwithout turning starting switch ON.
6 ness (Short circuit with GND
Wiring
harness between J1 (female) (26)
ResisMin.
circuit)
CAM SENSOR (female) (3)
tance
100 kz
a Prepare with starting switch OFF, then turn starting switch ON and
Hot short (Short circuit with
carry out troubleshooting.
7 5V, 24V circuit) in wiring harWiring harness between J1 (female) (26)
ness
Voltage Max. 1 V
CAM SENSOR (female) (3)
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between J1 (female) (26)
Short circuit in wiring harness CAM SENSOR (female) (3) and J1 (female)
8
(With another wiring harness) (37) CAM SENSOR (female) (1)
Resistance
Min.
100 kz
Resistance
Min.
100 kz
38
114E-3 Series
40 Troubleshooting
Causes
Possible causes
and standard
value in normal 10 Defective engine controller
state
SEN00460-01
Voltage
Power supply
4.75 5.25 V
114E-3 Series
39
SEN00460-01
40 Troubleshooting
Failure code
1633
CA1633
Contents of
trouble
Trouble
Abnormality in KOMNET
Engine controller detected abnormality in KOMNET communication circuit to controllers on applicable machine side.
Action of controller
Problem that
appears on
machine
KOMNET communication information may not be transmitted correctly to cause incorrect operation
of machine.
(Problem depends on failure occurrence location.)
Related information
Causes
Resistance
Max. 1 z
Resistance
Max. 1 z
Possible causes
and standard
value in normal
state
Min. 1 Mz
Resistance
Min. 1 Mz
40
Resistance
Voltage
Max.
5.5 V
Voltage
Max.
5.5 V
Resistance
47 67 z
114E-3 Series
40 Troubleshooting
SEN00460-01
114E-3 Series
41
SEN00460-01
40 Troubleshooting
Failure code
2185
CA2185
Contents of
trouble
Trouble
High voltage (min. 5.25 V) occurred in throttle sensor power supply circuit.
Action of controller
Problem that
appears on
machine
Related information
Causes
Resistance
Min.
100 kz
Resistance
Min.
100 kz
Connecting parts among fuel control dial, engine unit wiring harness, and engine controller are suspected. Inspect them directly.
Loose connector, broken lock, broken seal
Corrosive, bent, broken, forced-in, or extended pin
Humidity in connector, entry of dirt or dust, poor insulation
If causes 1 and 2 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried
out.)
42
114E-3 Series
40 Troubleshooting
SEN00460-01
Failure code
2186
CA2186
Contents of
trouble
Trouble
Action of controller
Problem that
appears on
machine
Related information
Causes
a Troubleshoot with starting switch OFF, then carry out troubleGround fault in wiring harshooting without turning starting switch ON.
1 ness (Short circuit with GND
Wiring
harness between J2 (female) (22)
ResisMin.
circuit)
P20 (female) (1)
tance
100 kz
Possible causes
and standard
value in normal
state
a Troubleshoot with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness among all pins between J2
(female) (9) J2 (female) (With P20 disconnected)
Resistance
Min.
100 kz
Connecting parts among fuel control dial, engine unit wiring harness, and engine controller are suspected. Inspect them directly.
Loose connector, broken lock, broken seal
Corrosive, bent, broken, forced-in, or extended pin
Humidity in connector, entry of dirt or dust, poor insulation
If causes 1 3 are not detected, engine controller may be defective.
(Since trouble is in system, troubleshooting cannot be carried out.)
114E-3 Series
43
SEN00460-01
40 Troubleshooting
Failure code
2249
CA2249
Contents of
trouble
Trouble
Action of controller
Problem that
appears on
machine
Related information
Possible causes
and standard
value in normal
state
44
Causes
1
114E-3 Series
40 Troubleshooting
114E-3 Series
SEN00460-01
45
SEN00460-01
40 Troubleshooting
Failure code
2265
CA2265
Contents of
trouble
Trouble
Action of controller
None in particular.
Problem that
appears on
machine
Related information
Causes
Defective electric lift pump
1 (Internal short circuit, disconnection)
Resistance
Max. 20 z
Disconnection in wiring harness (Disconnection in wiring Wiring harness between J1 (female) (1)
2
or defective contact in con- LIFT PUMP (female) (1)
nector)
Wiring harness between J1 (female) (11)
LIFT PUMP (female) (2)
Possible causes
and standard
value in normal
state
46
Resistance
Max. 10 z
Resistance
Max. 10 z
Voltage
Max. 6 V
Resistance
Min.
100 kz
Resistance
Max. 20 z
114E-3 Series
40 Troubleshooting
SEN00460-01
114E-3 Series
47
SEN00460-01
40 Troubleshooting
Failure code
2266
CA2266
Contents of
trouble
Trouble
Action of controller
None in particular.
Problem that
appears on
machine
Related information
Causes
Resistance
Max. 20 z
Min. 100 kz
Possible causes
and standard
value in normal
state
Voltage
Max. 6 V
Resistance
Min.
100 kz
48
J1 (female)
Resistance
Max. 20 z
Min. 100 kz
114E-3 Series
40 Troubleshooting
SEN00460-01
114E-3 Series
49
SEN00460-01
40 Troubleshooting
Failure code
2311
CA2311
Contents of
trouble
Action of
controller
Trouble
Problem that
appears
on machine
Related information
Causes
1 Defective related system
Resistance
Max. 5 z
Min. 100 kz
Possible
causes and
standard value
in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between J1 (female) (2)
3
or defective contact in con- CP3 PUMP REGULATOR (female) (1)
nector)
Wiring harness between J1 (female) (32)
CP3 PUMP REGULATOR (female) (2)
Resistance
Max. 5 z
Resistance
Max. 5 z
Connecting parts among supply pump actuator, engine wiring harness, and engine controller are suspected. Inspect them directly.
Loose connector, broken lock, broken seal
Corrosive, bent, broken, forced-in, or extended pin
Humidity in connector, entry of dirt or dust, poor insulation
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
50
J1 (Female)
Resistance
Max. 5 z
Min. 100 kz
114E-3 Series
40 Troubleshooting
SEN00460-01
114E-3 Series
51
SEN00460-01
40 Troubleshooting
E-55 Code [2555/CA2555] Intake Air Heater Relay Supply Voltage Low
Error
1
Error code
Failure code
2555
CA2555
Contents of
trouble
Action of
controller
Trouble
Problem that
appears
on machine
Related information
Method of reproducing failure code: Starting switch ON when coolant temperature is 4C or less.
Causes
Resistance
Possible
causes and
standard value
in normal state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between J2 (female) (40)
2
or defective contact in con- R18 (female) (1)
nector)
Wiring harness between J2 (female) (42)
R18 (female) (2)
Short circuit in wiring har3 ness (With another wiring
harness)
52
Resistance
Max. 10 z
Resistance
Max. 10 z
a Troubleshoot with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness among all pins between J2
(female) (40) J2 (female) (With also R18
disconnected)
Resistance
Min.
100 kz
Connecting parts among auto preheat relay, engine unit wiring harness, and engine controller are suspected. Inspect them directly.
Loose connector, broken lock, broken seal
Corrosive, bent, broken, forced-in, or extended pin
Humidity in connector, entry of dirt or dust, poor insulation
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
J2 (female)
Resistance
300 600 z
114E-3 Series
40 Troubleshooting
SEN00460-01
114E-3 Series
53
SEN00460-01
40 Troubleshooting
E-56 Code [2556/CA2556] Intake Air Heater Relay Supply Voltage High
Error
1
Error code
Failure code
2556
CA2556
Contents of
trouble
Action of
controller
Trouble
Problem that
appears
on machine
Related information
Method of reproducing failure code: Starting switch ON when coolant temperature is 4C or less.
Causes
Resistance
Possible
causes and
standard value
in normal state
54
a Troubleshoot with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness among all pins between J2
(female) (40) J2 (female) (With also R18
disconnected)
Resistance
Min.
100 kz
Connecting parts among auto preheat relay, engine unit wiring harness, and engine controller are suspected. Inspect them directly.
Loose connector, broken lock, broken seal
Corrosive, bent, broken, forced-in, or extended pin
Humidity in connector, entry of dirt or dust, poor insulation
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
J2 (female)
Resistance
300 600 z
114E-3 Series
40 Troubleshooting
SEN00460-01
114E-3 Series
55
SEN00460-01
40 Troubleshooting
Failure code
---
B@BAZG
Contents of
trouble
Trouble
Action of controller
Limits output and continues operation (Limits fuel injection rate and engine speed).
Problem that
appears on
machine
Output drops.
Related information
Possible causes
and standard
value in normal
state
Causes
1
Failure code
---
B@BAZG
Contents of
trouble
Action of
controller
Problem that
appears
on machine
Trouble
Related information
Possible
causes and
standard value
in normal state
56
Causes
1
114E-3 Series
40 Troubleshooting
SEN00460-01
Failure code
---
B@BCNS
Contents of
trouble
Action of
controller
Problem that
appears
on machine
Trouble
Engine overheat
Related information
Possible
causes and
standard value
in normal state
114E-3 Series
Causes
1
57
SEN00460-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 05-07 (01)
58
SEN00458-01
ENGINE
1SHOP MANUAL
114E-3 Series
40 Troubleshooting
114E-3 Series
SEN00458-01
40 Troubleshooting
114E-3 Series
40 Troubleshooting
SEN00458-01
The troubleshooting chart consists of the questions, check items, causes, and troubleshooting blocks.
The questions and check items are used to pinpoint
high probability causes by simple inspection or
from phenomena without using troubleshooting
tools.
Next, troubleshooting tools or direct inspection are
applied to check the narrowed causes in order from
the most probable one to make final confirmation
according to the troubleshooting procedure.
[Questions]:
Items to be drawn from the user or operator.
They correspond to A and B in the chart on the
right.
The items in A are basic ones.
The items in B can be drawn from the user or
operator, depending on their level.
[Check items]:
Items to be simply checked by the serviceman
to narrow down causes.
They correspond to C in the chart on the right.
[Causes]:
Items to be narrowed from the questions and
check items.
The serviceman narrows down the probable
causes from A, B, and C.
[Troubleshooting]:
Items to finally verify whether the narrowed
down causes are undoubtedly the real causes
using the troubleshooting tools and direct
inspections.
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, or w.
E : Causes to be referred to for questions and check items
Q : Causes related to questions and check items
w : Causes highly probable among ones marked with Q
a When narrowing the causes, apply the items marked with w before those marked with Q.
When narrowing the causes, do not apply the items marked with E. (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
114E-3 Series
SEN00458-01
40 Troubleshooting
114E-3 Series
40 Troubleshooting
SEN00458-01
If we look from these 3 symptoms to find the causes, we find that there is a relationship with 5 causes. Let us
explain here the method of using this causal relationship to pinpoint the most probable cause.
114E-3 Series
SEN00458-01
40 Troubleshooting
Defective injector
Causes
Q w w
E
w
Q Q
Replacement of filters has not been carried out according to Operation and Mainte- w
nance Manual
w Q
During operation, charge level monitor indicates abnormal charge (if monitor is
installed)
w w
w
Q
w
Check items
w
w
w
Q Q
w
Q w Q
q q
Troubleshooting
Carry out troubleshooting according to No-pressure feed by supply pump (*1) in Emode
Carry out troubleshooting according to Abnormality in electric lift pump (*2) in Emode
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change
When starting switch is turned to HEAT, intake air heater mount does not become
warm
Is voltage 20 30 V between alternator terminal B and terminal E with
engine at low idle?
q
q
Yes
No
When specific gravity of electrolyte and voltage of battery are measured, they are
low
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Correct
Replace
Clean
Replace
Remedy
q
Replace
Questions
Starting performance
114E-3 Series
40 Troubleshooting
SEN00458-01
EE
Q
w
w
w
Q
When starting switch is turned to START, starting pinion does not move out
w
w
Q Q
114E-3 Series
q
q
q
q
Causes
Replace
Replace
Correct
Replace
Replace
Replace
Replace
Troubleshooting
Check items
Questions
SEN00458-01
40 Troubleshooting
Causes
E
Q
q
q
q q
q
q
q
q
q
Replace
Add
Clean
Correct
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Troubleshooting
Check items
Questions
114E-3 Series
40 Troubleshooting
SEN00458-01
Causes
Questions
E
w
w
w
w
w
Q
w
Check items
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
w
q
q
q
Coolant temperature gauge does not indicate normally (if coolant temperature gauge is installed)
When starting switch is turned to HEAT, intake air heater mount does not
become warm
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Replace
Replace
Replace
Clean
Remedy
q
Replace
SEN00458-01
40 Troubleshooting
1
Clogged air cleaner element
Defective contact of valve and valve seat
Improper valve clearance
Seized turbocharger, interference of turbocharger
Worn piston ring, cylinder liner
Clogged air breather hole of fuel tank cap
Leaking or clogged fuel piping, entry of air
Clogging of fuel filter
Stuck, seized supply pump plunger
Clogged injector, defective spray
Causes
E
w
E
Q Q
w
w
w
w
w
Q
w w w
Q w
w
w
Q
q
q
q
q
Clean
Replace
Adjust
Replace
Replace
Clean
Correct
Replace
Replace
Replace
Troubleshooting
Check items
Questions
10
114E-3 Series
40 Troubleshooting
SEN00458-01
Causes
w w w w
w Q
w Q
Q Q
Q Q
Replacement of filters has not been carried out according to Operation and
Maintenance Manual
w
w
w w
w
w
q q
Remedy
Replace
Replace
Replace
Replace
Add
Clean
Correct
Replace
Replace
Replace
Replace
Replace
Troubleshooting
Check items
Q w Q w
Questions
11
SEN00458-01
40 Troubleshooting
1
Insufficient fuel in tank
Clogged air breather hole of fuel tank cap
Leaking or clogged fuel piping, entry of air
Clogging of fuel filter
Clogged injector, defective spray (dirt in injector)
Defective Ne speed sensor, wiring harness
Defective Bkup speed sensor, wiring harness
Causes
E
Q Q
Q Q Q Q Q
Q
Q Q
w
w
w
w
Q
w
q
q
q
q
Add
Clean
Correct
Replace
Replace
Replace
Replace
Troubleshooting
Check items
Questions
12
114E-3 Series
40 Troubleshooting
SEN00458-01
Causes
Q w
Q
Gradually
Q Q Q Q
Replacement of filters has not been carried out according to Operation and Maintenance Manual
w
Q
w w
Black
w
w
Check items
w w
w
High idle speed under no load is normal, but speed suddenly drops when load is applied
w w
w Q Q
Q Q
Q Q Q
Q Q
q q q
q
q
Q Q Q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change
q q
q
Correct
Replace
Replace
Replace
Replace
Correct
Clean
Replace
Adjust
Replace
Replace
Clean
Correct
Remedy
q
Replace
Replace
Questions
13
SEN00458-01
40 Troubleshooting
1
Defective coolant temperature sensor, wiring harness
Causes
Questions
Q
w
Q Q
E
Q Q Q
Suddenly
Q
Gradually
Q
Q
Q Q
Q
Muffler is crushed
w
Q Q
Check items
When exhaust manifold is touched immediately after starting engine, temperature of some
cylinders is low
Q w
w
Torque converter stall speed or pump relief speed is high (Fuel is injected excessively)
Exhaust noise is abnormal
Q Q Q
Q
Q w
w
Troubleshooting
q
q
Carry out troubleshooting according to No-pressure feed by supply pump (*1) in E-mode
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change
q
q
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Replace
Clean
Replace
Remedy
Replace
Replace
14
114E-3 Series
40 Troubleshooting
SEN00458-01
Causes
EEE
E
w
Q
Q
w
Q Q w
w w w w w
w
w
Q w
w
w
Q
w w
w w
Q
w
114E-3 Series
Correct
Replace
Replace
Replace
Clean
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Troubleshooting
Check items
Questions
15
SEN00458-01
40 Troubleshooting
1
Defective seal at turbocharger turbine end
Worn valve, valve guide
Worn piston ring, cylinder liner
Clogged breather, breather hose
Clogged oil cooler
Clogged oil filter
Defective oil filter safety valve
Clogged turbocharger lubrication drain tube
Exhaust smoke is bad
Causes
EEE
Q
w
Q Q
w
w
w
w
w
Q Q w
Q
w
q q
See S-7
q
q
q
q
q
Remedy
16
Replace
Replace
Replace
Clean
Clean
Replace
Replace
Clean
Troubleshooting
Check items
Questions
114E-3 Series
40 Troubleshooting
SEN00458-01
1
Fuel leakage inside head cover
Fuel leakage from fuel filter, piping, etc.
Defective feed pump oil seal
Defective supply pump plunger
Defective common rail pressure
Defective spray by injector
Defective operation of injector
Defective coolant temperature sensor, wiring harness
Causes
q
q
q
q
q
q
Correct
Correct
Replace
Replace
Correct
Replace
Replace
Replace
Troubleshooting
Check items
Questions
114E-3 Series
17
SEN00458-01
40 Troubleshooting
S-11 Oil is in coolant (or coolant spurts back or coolant level goes
down)
Suddenly rose
Oil level
Gradually rose
Hard water is being used as coolant
Oil level has risen and oil is milky
Q
Q Q
Q Q
Q Q w
q q
Replace
Replace
Replace
Replace
Carry out
troubleshooting
on applicable
machine
Remedy
18
Check items
Causes
Troubleshooting
Questions
114E-3 Series
40 Troubleshooting
SEN00458-01
1
Worn journal of bearing
Lack of oil in oil pan
Coolant, fuel in oil
Clogged strainer in oil pan
Clogged, broken pipe in oil pan
Defective oil pump
Defective regulator valve
Clogged oil filter
Leaking, crushed, clogged hydraulic piping
Defective oil level sensor, wiring harness
Causes
w w w Q
w
Q
w
w
w
w
w
q
q q
q
q
q
q
Remedy
114E-3 Series
E
Q w
Q
w
See S-13
Replace
Add
Clean
Correct
Replace
Adjust
Replace
Correct
Replace
Check items
Troubleshooting
Questions
19
SEN00458-01
40 Troubleshooting
1
Broken cylinder head, head gasket
Broken injector, O-ring
Cracks inside cylinder block
Holes caused by pitting
Worn, damaged rear oil seal
Broken oil cooler core, O-ring
Defects in supply pump
Defective seal of auxiliary equipment (pump, compressor)
Causes
EE
Q
Q
Q Q Q Q
w
Q
Q
Q
w
E
w
w
w
Q
Q
w
w
q
q q
q
q
q
q
Remedy
20
E
w
Replace
Correct
Replace
Replace
Replace
Replace
Replace
Replace
Troubleshooting
Check items
Questions
114E-3 Series
40 Troubleshooting
SEN00458-01
Causes
w
w
w
w
w
w
w
Remedy
q
q
q
q
q
q
q
q
Troubleshooting
114E-3 Series
Q
Q
Replace
Replace
Replace
Add
Replace
Replace
Correct
Correct
Replace
Correct
Replace
Check items
Questions
21
SEN00458-01
40 Troubleshooting
Causes
Gradually occurred
Q
Q
w
w
w
w
Q Q
Suddenly occurred
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
Exhaust smoke color
w Q
w
Black
Q
w
Q Q
q q
q q
q
Remedy
22
Correct
Replace
Replace
Replace
Adjust
Replace
Replace
Replace
Correct
Replace
Replace
Replace
Questions
114E-3 Series
40 Troubleshooting
SEN00458-01
Q
Q
w
w
Q
Q
Q
w
w
Q
Q
Q
Q Q Q
Q
w
q
q
q
q
q
q
Replace
Adjust
Replace
Replace
q
Remedy
114E-3 Series
Causes
Replace
Replace
Replace
Replace
Troubleshooting
Check items
Questions
23
SEN00458-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 05-07 (01)
24
SEN00462-01
ENGINE
1SHOP MANUAL
114E-3 Series
114E-3 Series
SEN00462-01
Disassembly
q
In Disassembly section, the work procedures,
precautions and know-how for carrying out
those procedures, and quantity of the oil and
coolant drained are described.
q
The meanings of the symbols used in Disassembly section are as follows.
k : Precautions related to safety in execution
of work.
a : Know-how or precautions for work.
6
Assembly
q
In Assembly section, the work procedures, precautions and know-how for carrying out those
procedures, and quantity of the oil and coolant
added are described.
q
The meanings of the symbols used in Assembly section are as follows.
k
114E-3 Series
SEN00462-01
(Rev. 2007/04)
1
a
a
The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below.
For coating materials not listed below, use the equivalent of products shown in this manual.
Category
Komatsu
code
Part number
Q'ty
Container
LT-1A
790-129-9030
150 g
Tube
Used to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.
LT-1B
790-129-9050
20 g
(2 pcs.)
LT-2
09940-00030
50 g
Adhesive
LT-3
LT-4
790-129-9040
250 g
Holtz MH 705
790-129-9120
75 g
ThreeBond
1735
790-129-9140
Polyethylene
Used to seal plugs.
container
Tube
50 g
Quick-setting adhesive.
Quick-setting type.
Polyethylene
(max. strength is obtained after 30 minutes)
container
Used mainly to stick rubbers, plastics, and
metals.
790-129-9130
2g
Loctite
648-50
79A-129-9110
50 cc
LG-1
790-129-9010
200 g
790-129-9080
Can
Quick-setting adhesive.
Polyethylene Setting time: Within 5 sec. to 3 min.
container Used mainly to stick metals, rubbers, plastics,
and woods.
Aron-alpha
201
LG-5
Gasket sealant
790-129-9060
Adhesive: 1 kg
(Set of adhesive
Hardener: 500 g
and hardener)
1 kg
LG-6
790-129-9020
200 g
Tube
LG-7
790-129-9070
1 kg
Tube
Tube
LG-8
ThreeBond
1207B
114E-3 Series
419-15-18131
100 g
SEN00462-01
Seizure
prevention
compound
Molybdenum
disulfide lubricant
Gasket sealant
CateKomatsu code
gory
Part number
Q'ty
Container
LG-9
ThreeBond
1206D
790-129-9310
200 g
Tube
LG-10
ThreeBond
1206E
790-129-9320
200 g
Tube
LG-11
ThreeBond
1121
790-129-9330
200 g
Tube
ThreeBond
1211
790-129-9090
100 g
Tube
LM-G
09940-00051
60 g
Can
Tube
Used to prevent scuffing and seizure of press-fitted portions, shrink-fitted portions, and threaded
portions.
Used to lubricate linkages, bearings, etc.
Can
Feature: Seizure and scuffing prevention compound with metallic super-fine-grain, etc.
Used for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.
Various
Various
LM-P
LC-G
NEVER-SEEZ
09940-00040
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI
SYGA-160CNLI
*: For cold district
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
200 g
Grease
Molybdenum
SYG2-400M
disulfide grease SYG2-400M-A
LM-G (G2-M)
SYGA-16CNM
SYG2-400T-A
SYG2-16CNT
SYG0-400T-A (*)
*: For cold district SYG0-16CNT (*)
Hyper White
Grease G2-T,
G0-T (*)
SYG2-400B
Biogrease
G2-B, G2-BT (*) SYGA-16CNB
*: For use at high SYG2-400BT (*)
temperature and SYGA-16CNBT
under high load
(*)
G2-S
ThreeBond
1855
Caution:
400 g x 10 Bellows-type Do not apply grease to rolling bearings like
400 g x 20 container
swing circle bearings, etc. and spline.
16 kg
Can
The grease should be applied to work equipment
pins at their assembly only, not applied for
greasing afterwards.
400 g
16 kg
400 g
16 kg
200 g
Bellows-type
container
Can
Tube
Feature: Silicone grease with wide using temperature range, high resistance to thermal-oxidative degradation and performance to prevent
deterioration of rubber and plastic parts.
Used for oil seals of the transmission, etc.
114E-3 Series
Part number
SUNSTAR
PAINT PRIMER
580 SUPER
SUNSTAR
PAINT PRIMER
435-95
Container
20 ml
Glass
container
20 ml
Glass
container
20 ml
Glass
container
417-926-3910
22M-54-27230
SUNSTAR
GLASS
PRIMER
435-41
22M-54-27240
150 ml
Can
SUNSTAR
SASH PRIMER
GP-402
22M-54-27250
20 ml
Glass
container
SUNSTAR
PENGUINE
SEAL 580
SUPER S or
W
417-926-3910
320 ml
Polyethylene
container
Sika Japan,
Sikaflex 256HV
20Y-54-39850
310 ml
Polyethylene
container
SUNSTAR
PENGUINE
SUPER 560
22M-54-27210
320 ml
Ecocart
(Special
container)
SUNSTAR
PENGUINE
SEAL No. 2505
417-926-3920
320 ml
Polyethylene
container
SEKISUI
SILICONE
SEALANT
20Y-54-55130
333 ml
Polyethylene
container
Cartridge
GE TOSHIBA
SILICONES
TOSSEAL 381
114E-3 Series
22M-54-27220
333 ml
Caulking material
Adhesive
Primer
SUNSTAR
GLASS
PRIMER 580
SUPER
Q'ty
CateKomatsu code
gory
SEN00462-01
SEN00462-01
a
a
a
a
a
Tools with part number 79QTQQQ-QQQQ cannot be supplied (they must be locally manufactured)
Necessity : t.............. Cannot be substituted, should always be installed (used)
: q.............. Extremely useful if available, can be substituted with commercially available
parts
New/Remodel : N....... Tools newly developed for this model and given new part Nos.
: R .............. Tools remodeled from tools already available for other models and given
upgraded part Nos.
: Blank........ Tools already available for other models, usable without any modification
Tools marked with Q in the sketch column are tools introduced in the sketches of the special tools
(See Sketches of special tools)
Nos. in the upper line of the Part No. column are KOMATSU part Nos. and those in the lower line are
CUMMINS part Nos.
Work item
Symbol
A
Disassembly and assembly
of engine assembly
Part No.
790-501-2001
795-799-1150
Part name
Repair stand
Necessity
Q'ty
New / Remodel
Sketch
a
a
a
t 1
Adapter
t 1
Spring pusher
q 1
795-799-2280
Removal and installation of
air intake valve and exhaust
valve
t 1
Installation of piston
t 1
Removal of injector
795-799-6700 Puller
t 1
Commercially
Clearance gauge
available
q 1
Commercially
Dial gauge stand
available
q 1
795-799-8150 Remover
q 1
q 1 N
795-799-1390 Remover
q 1
q 1 N
795-102-2103
795-799-8800
790-331-1120
795-799-2240
Wrench (angle)
75 175 mm
q 1
q 1
2 795-799-2310 Extension
q 1
q 1
q 1 N
Remarks
114E-3 Series
Work item
Symbol
SEN00462-01
Part No.
Part name
Necessity
Q'ty
New / Remodel
Sketch
Rotating crankshaft
q 1
q 1
795-790-2210 Gauge
q 1
q 1
114E-3 Series
Remarks
SEN00462-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 05-07 (01)
SEN00463-01
ENGINE
1SHOP MANUAL
114E-3 Series
114E-3 Series
SEN00463-01
1.
Preparation work
Before disassembling the engine, check its
parts for cracking, damage, etc. and clean it
generally and carefully for accurate inspection
of its parts and quick disassembly and assembly.
a Before cleaning the engine, carefully seal
or remove the openings, electric parts,
and wiring connectors so that water will
not enter them.
q
Prepare stable engine stands (Blocks [1])
and secure engine assembly (1) on them
so that it will not tip over.
1)
2)
3)
4)
1
2.
2)
3)
Install tool B.
3 Mounting bolt on engine side
Position of
bolt
Size of bolt
Tightening
torque
M8
24 4 Nm
{2.5 0.4 kgm}
b, c
M10
43 6 Nm
{4.4 0.6 kgm}
114E-3 Series
SEN00463-01
k
3.
4.
6.
Alternator
1) Remove mounting bolts (2) and alternator
(1).
2) Remove bracket (3).
5.
7.
Belt tensioner
Remove mounting bolt (1) and belt tensioner
(2).
114E-3 Series
SEN00463-01
8.
Oil cooler
q
Before removing the oil cooler, place an oil
receiver under it.
1) Remove cover (1) and cover gasket (2).
2) Remove oil cooler (3) and cooler gasket
(4).
9.
Coolant connector
1) Remove coolant outlet connector (1).
2) Remove coolant inlet connector (2).
10. Thermostat
Remove thermostat (1).
2)
114E-3 Series
3]
4]
3)
114E-3 Series
SEN00463-01
2)
SEN00463-01
2)
3)
4)
114E-3 Series
5)
6)
SEN00463-01
Record the position of each crosshead and the shapes of holes (a) and
(b).
114E-3 Series
SEN00463-01
2)
Yellow
Orange
Red
Brown
Cylinder No.
1, 3, 5
2, 4, 6
Right side
Left side
Right side
Left side
3)
4)
114E-3 Series
4)
SEN00463-01
1)
3)
114E-3 Series
SEN00463-01
4)
3)
4)
5)
2)
10
114E-3 Series
SEN00463-01
1]
2]
114E-3 Series
2)
11
SEN00463-01
31. Camshaft
a Rotate the crankshaft and set the mark of
camshaft gear assembly (1) to the mark of
crankshaft gear (2).
12
1)
2)
32. Tappet
q
Turn over the engine.
Remove 12 tappets (1).
114E-3 Series
SEN00463-01
3)
4)
5)
7)
2]
6)
Push in and remove the piston and connecting rod assembly with a wood bar, etc.
from the oil pan side, while supporting piston (4) on the cylinder head side.
a Take care not to damage the inside of
the cylinder with a corner of the connecting rod.
a Make a cylinder No. mark on the piston.
114E-3 Series
13
SEN00463-01
3]
4]
5]
2)
35. Flywheel
1) Install lock plate [1] and remove mounting
bolt (1).
14
114E-3 Series
2)
SEN00463-01
3)
4)
39. Crankshaft
a Before removing the crankshaft, measure
its end play with tool L.
1)
2)
114E-3 Series
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5)
6)
1)
7)
16
Make mark (A) of the cylinder liner position and insert tool R from above the cylinder block.
a Set arms [5] so that they will not touch
supports [1], [2], [3], and [4] of cylinder liner (1).
a Set tool R so that it will be at the center of the top of the cylinder liner.
114E-3 Series
2)
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114E-3 Series
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2007 KOMATSU
All Rights Reserved
Printed in Japan 05-07 (01)
18
SEN00464-01
ENGINE
1SHOP MANUAL
114E-3 Series
114E-3 Series
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a
1.
Size of bolt
Tightening torque
M8
24 4 Nm
{2.5 0.4 kgm}
b, c
M10
43 6 Nm
{4.4 0.6 kgm}
2)
2.
1)
Cylinder liner
a Before inserting the cylinder liner, clean it,
remove all deposits and broken pieces
from sealing faces (A), (B), and (C), and
polish those faces until the machined surfaces appear. (Take care not to scrub too
much.)
q
Apply clean engine oil (EO15W-40) to
faces (A) and (B).
2)
114E-3 Series
3)
4)
5)
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7)
3.
Tappet
q
Turn over the cylinder block.
a When reusing the camshaft and tappets,
be sure to combine them as they were.
a Do not install a used tappet to a new camshaft.
1) Apply engine oil (EO15W-40) to the tappet.
2)
6)
After press fitting the cylinder liner, measure the projection of the cylinder liner
with tool L.
a Measure the projection at 4 places
equally spaced on the periphery.
a Projection of liner: 0.026 0.122 mm
114E-3 Series
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4.
5.
Crankshaft
1) Install 6 upper bearings (7) and 1 upper
thrust bearing (6).
a Set the projection of each bearing to
the cut of the cylinder block.
a When installing the bearings, check
that their back sides are free from foreign matter.
a Apply engine oil (EO15W-40) to the
inside of the bearings. Do not apply it
to the back side, however.
a When reusing the bearings, check the
marks made on them when removed
and install them to their original positions.
2)
3)
114E-3 Series
4)
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5)
6)
1]
2]
3]
4]
5]
7)
8)
114E-3 Series
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3)
4)
9)
6.
2)
5)
6)
114E-3 Series
7)
1]
2]
3]
114E-3 Series
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8)
9)
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7.
2)
q
114E-3 Series
8.
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3)
Oil pump
a Fill the space in the pump rotor and idler
shaft bore with engine oil (EO15W-40)
and rotate the rotor by 2 turns.
1)
Camshaft
a Rotate the crankshaft to set the No. 1 cylinder to the top dead center.
1) Apply engine oil (EO15W-40) to the camshaft bore, camshaft journal, and lobe,
and then install camshaft gear assembly
(1) while lightly pushing and rotating it.
Set oil pump idler shaft (3) in the positioning hole of the cylinder block
securely.
2)
2)
Measuring backlash
Rotate the crankshaft by 1 turn and measure backlash (C) between the pump and
idler gear.
a Backlash (C): 0.205 0.125 mm
114E-3 Series
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3)
4)
5)
10
114E-3 Series
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3)
2)
114E-3 Series
Surface of flange:
Gasket sealant (LG-7)
q
Tighten the mounting bolts in the
numerical order shown below: [1]
[5]
3 Mounting nut:
9.8 2.0 Nm {1.0 0.2 kgm}
11
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3)
4)
2)
Position of bolt
Size of bolt
Tightening
torque
12
114E-3 Series
2)
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2)
3)
4)
114E-3 Series
5)
13
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6)
7)
3)
2)
14
Apply gasket sealant to the bed plate mating face shown in the figure and install
gasket (6).
2 Gasket (Mating face of bed plate):
Gasket sealant (LG-7)
a Apply gasket sealant (strings) similarly to step 2).
114E-3 Series
4)
5)
6)
114E-3 Series
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7)
15
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16
2)
3)
After installing the flywheel housing, measure the radial runout and facial runout
with tool L.
q
Radial runout: Max. 0.20 mm
q
Facial runout: Max. 0.20 mm
18. Flywheel
1) Install guide bolt [1] and flywheel (1).
q
Apply a string of gasket sealant 1 3
mm in diameter around the bolt holes
on the crankshaft mounting face (8
places).
2 Flywheel mounting face:
Gasket sealant (LG-7)
4 Flywheel assembly: 40 kg
114E-3 Series
2)
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2)
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3)
18
114E-3 Series
2]
3]
4]
114E-3 Series
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2)
3)
19
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4)
20
114E-3 Series
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1)
2)
3)
4)
5)
6)
114E-3 Series
21
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7)
8)
9)
22
114E-3 Series
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3)
4)
Unit: mm
1)
Intake valve
Exhaust valve
0.30 0.05
0.56 0.05
2)
While the No. 1 cylinder is at the compression top dead center, adjust the valve
clearances marked with q in the valve
arrangement drawing.
5)
114E-3 Series
While the No. 6 cylinder is at the compression top dead center, adjust the valve
clearances marked with Q in the valve
arrangement drawing.
a Adjust the valve clearance according
to steps 3) and 4) above.
23
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3)
Install the injector wiring harness terminal (5) in a direction where it will
not interfere with the rocker arm (6)
which moves up and down.
24
Yellow
Orange
Red
Brown
Cylinder No.
1, 3, 5
2, 4, 6
Right side
Left side
Right side
Left side
114E-3 Series
2)
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3)
4)
5)
114E-3 Series
25
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2)
3)
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114E-3 Series
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5]
2)
7]
8]
114E-3 Series
27
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3)
4)
5)
1)
2)
28
Install tubes (1) (6) between the common rail and injector.
3 Nut: 37.3 4 Nm {3.8 0.4 kgm}
a When installing the tubes to the No.
1, No. 3, and No. 5 cylinders, disconnect the wiring connector of the injector wiring harness.
6) Tighten drain tube (18) permanently.
3 Joint bolt:
24 4 Nm {2.4 0.4 kgm}
7) Tighten common rail (16) permanently.
3 Joint bolt:
43.1 4.0 Nm {4.4 0.4 kgm}
8) Tighten clamp (14) permanently.
9) Install bellows (8).
a Set the slits of each bellows out and
down.
a The bellows are installed so that fuel
will not spout over the hot parts of the
engine and catch fire when it leaks for
some reason.
10) Fit the gasket and install head cover
assembly (9).
3 Head cover assembly mounting
bolt:
11.8 1.96 Nm {1.2 0.2 kgm}
114E-3 Series
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114E-3 Series
29
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2)
3)
39. Thermostat
Fit the O-ring and install thermostat (1).
30
41. Alternator
1) Install brackets (3) and (4).
2) Install alternator (1) with mounting bolts
(5) and (6).
3 Mounting bolt (5):
43 6 Nm {4.4 0.6 kgm}
3 Mounting bolt (6):
24 4 Nm {2.4 0.4 kgm}
114E-3 Series
114E-3 Series
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2)
31
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3)
4)
5)
47. Muffler
1) Install plate (1).
2)
3)
4)
Place and fix engine assembly (1) on stable engine stand [1].
Install plates (3) and (5).
Install ground wire (4) of the main controller to plate (3).
32
114E-3 Series
SEN00464-01
33
SEN00464-01
2007 KOMATSU
All Rights Reserved
Printed in Japan 05-07 (01)
34